2005 TOYOTA AVENSIS manifold belt

031H2−02
03−14
− SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by−pass pipe No.1 x Cylinder block9.09280 in.
lbf
Water by−pass pipe No. 3 x Cylinder block9.09280 in.
lbf
Oil cooler pipe x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V−ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Exhaust manifold heat insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Drive plate & ring gear x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub−assy front x Body Bolt
Nut45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No. 2 RH x Transverse engine
engine mounting insulator A
B
52
11 3530
1,15238
83
Vane pump assy x Timing chain cover3737027
Front suspension arm sub−assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub−assy x Frame8.08271 in.
lbf
Radiator reserve tank Sub−assy x Body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 5
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Engine cover No. 1 x Cylinder head cover9.09280 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90 _806
Turn 90 _58
Turn 90 _
Camshaft timing oil control valve assy x Cylinder head9.09279 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Battery carrier x Frame131319.5
Battery clamp x Body Bolt
Nut5.0
3.551
3644 in. lbf
31 in. lbf
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14 −45) Bolt A
Bolt B
Bolt C
Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1 CD −FTV:
Part TightenedN
mkgf
cmft
lbf
Air tube No. 1 hose clamp bolt6.06153 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover sub −assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub −assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020014
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5657542
Compressor mounting bracket x Cylinder block4242831
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf

03−1 6
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Intake manifold x Cylinder head2120915
Power steering idle pulley bracket x Cylinder head
(See page 14 −108) Bolt A
Bolt B
72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe x injection pump With SST
Without SST
31
34316
34723
25
Nozzle leakage pipe No.2 x Cylinder head cover sub −assy8.89078 in.
lbf
Nozzle leakage pipe No.2 x Cylinder head8.89078 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2120915
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub −assy x Cylinder head2120915
Exhaust manifold x Cylinder head4747434
EGR pipe sub −assy x Cylinder head Bolt
Nut37
25375
25027
18
Vacuum pump oil pipe x Cylinder block Bolt Nut21
8.8214 9015
78 in.
lbf
Vacuum transmitting pipe No. 2 x Manifold converter
For nut With SST
Without SST
For bolt
27
30
25275
306
25520
22
18
Vacuum transmitting pipe No. 1 x Manifold converter
For nut With SST Without SST
For bolt
27
30
25275
306
25520
22
18
Exhaust gas temperature sensor x Manifold converter With SST
Without SST27
30275
30620
22
Exhaust gas temperature sensor x Vacuum transmitting pipe No. 26.46557 in.
lbf
Oil filter bracket x Oil pan sub −assy3434725
V −ribbed belt tensioner bracket x Cylinder block2020415
V −ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub −assy x V −ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub −assy center x Body4545933

05−302
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM 1045E)
DTC No.
(See Page) Memory
*
1
CHK ENG
Trouble Area
Detection Item
P0606
(05 −425)ECM/PCM Processor
ECM



P0607
(05 −425)Control Module Performance
SECM
ff
P0622
(05 −426)Generator Field ”F” Terminal Cir-
cuit
SOpen in generator (alternator) circuit
S Generator (alternator)
S Drive belt
S ECM
ff
P0627
(05 −429)Fuel Pump Control Circuit / Open
SOpen or shot in suction control valve circuit
S Suction control valve
S ECM
ff
P 1229
(05 −32 1)Fuel Pump System
S Short in supply pump (suction control valve) circuit
S Supply pump (suction control valve)
S ECM
ff
P 1238
(05 −43 1)Injector Malfunction
S Injector
S EDU (P0200 is set simultaneously)
S Open or short in engine wire harness (P0200 is set simulta-
neously)
S Connector connection (P0200 is set simultaneously)
S Compression pressure
S Valve clearance
S Valve timing
S ECM
ff
P 125 1
(05 −376)Turbo/Super Charger Overboost
Condition (Too High)
SVRV
S Open or short in VRV circuit
S Turbocharger
S EGR valve
S Vacuum hose
S ECM
ff
P 127 1
(05 −435)Fuel Regulator Circuit Malfunc-
tion (EDU Drive)
SOpen or short in pressure discharge valve circuit
S Open or short in pressure discharge valve itself
S EDU
S ECM
ff
P 1272
(05 −435)Fuel Pressure Regulator Mal-
function
SOpen or short in pressure discharge valve circuit (P 127 1is set
simultaneously)
S Pressure discharge valve
S Supply pump
S ECM
ff
P 1386
(05 −444)Injector For Exhaust Fuel Addi-
tion
SOpen or short in exhaust fuel addition injector circuit
S Exhaust fuel addition injector
S DPNR catalytic converter (Manifold converter sub −assy)
S Open in exhaust temperature sensor circuit
S A/F sensor
S Exhaust gas temperature sensor
S Supply pump assy
S Mass air flow meter
S Fuel leaks in exhaust fuel addition injector
S Main injector
S Cylinder compression pressure
S Valve clearance
S Valve timing
S Air intake system has blockages
S Air intake system has leakage
S Exhaust system has blockages
S Exhaust system has leakage
S EGR system has blockages
S EGR system has leakage
S ECM
ff

A85631
SST
A85632
A93406
SST
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
11−47
AVENSIS Supplement (RM1045E)
(b) Hold the hexagonal lobe of the exhaust fuel addition in-
jector assembly first. Using SST, remove the fuel pipe No.
3 from the injector side.
SST 09023−12700
(c) Remove the bolt and 3 nuts, then remove the fuel pipe No.
3 and 2 gaskets.
7. REMOVE INJECTION PIPE SUB−ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clamps
from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023−12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023−12700
(d) After removing the fuel pipe, to prevent dust or foreign ob-
jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
8. REMOVE INJECTION PIPE SUB−ASSY NO.2
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
9. REMOVE INJECTION PIPE SUB−ASSY NO.3
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
10. REMOVE INJECTION PIPE SUB−ASSY NO.4
SST 09023−12700
HINT:
Perform the same procedures as the injection pipe No. 1.
11. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover.

A84290
A84291
A15985
A84397
(a)
(a)
(b)
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −11 5
AVENSIS Supplement (RM1045E)
70. REMOVE V −RIBBED BELT TENSIONER ASSY
(a) Remove the 3 bolts and V −ribbed belt tensioner.
71. REMOVE V −RIBBED BELT TENSIONER BRACKET
(a) Remove the bolt and V −ribbed belt tensioner bracket.
72. REMOVE OIL FILTER BRACKET SUB −ASSY
(a) Remove the bolt and 2 nuts, then remove the oil filter
bracket and gasket.
73. REMOVE TURBO INSULATOR NO.2 (See page 13 −12)
74. REMOVE TURBO INSULATOR NO.1 (See page 13 −12)
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
76. REMOVE EGR PIPE INSULATOR (See page 13 −12)
77. REMOVE EXHAUST GAS TEMPERATURE SENSOR
(a) Remove the 2 nuts, then detach the wire harness from the clamp.
(b) Disconnect the connector.

A79150
A09671
A84294
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −121
AVENSIS Supplement (RM1045E)
104. REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a) Remove the 2 bolts and intake manifold insulator.
105. REMOVE COMMON RAIL ASSY (See page 11 −67)
106. REMOVE INTAKE MANIFOLD
(a) Remove the 8 bolts and 2 nuts, then remove the intake manifold and gasket.
107. REMOVE INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
108. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, then remove the timing belt cover.
109. REMOVE OIL LEVEL GAGE GUIDE (See page 17 −11 )
110. REMOVE INJECTION PUMP STAY NO.1 (See page 11 −58)
111. REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
112. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
(a) Remove the 4 bolts and compressor mounting bracket.
113. REMOVE WATER INLET (See Pub. No. RM1018E on page 16 −50)
114. REMOVE THERMOSTAT
115. REMOVE OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, remove the union bolt,oil cooler pipe and gasket.

A85921
5mm
(0.20 in.)
A85914
SST
A8592215 mm (0.59 in.)
A87961
SST
14−128−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
159. INSTALL EXHAUST GAS TEMPERATURE SENSOR
(a) Temporarily install the 3 nuts and exhaust gas tempera- ture sensor on down stream as shown in the illustration.
NOTICE:
Keep 5 mm (0.20 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(b) Using SST, tighten the sensor on the manifold converter
side.
SST 09023 −38400
Torque:
27 N
m (275 kgf
cm, 20 ft
lbf) with SST
30 N
m (306 kgf
cm, 22 ft
lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(c) Tighten the 3 nuts.
Torque: 6.4 N
m (65 kgf
cm, 57 in.
lbf)
(d) Temporarily install the 2 nuts and exhaust gas tempera- ture sensor on up stream as shown in the illustration.
NOTICE:
Keep 15 mm (0.59 in.) of the clearance between the exhaust
gas temperature sensor and vacuum transmitting pipe.
(e) Using SST, tighten the sensor on the manifold converter side.
SST 09023 −38400
Torque:
27 N
m (275 kgf
cm, 20 ft
lbf) with SST
30 N
m (306 kgf
cm, 22 ft
lbf) without SST
HINT:
Use a torque wrench with the fulcrum length of 30 cm (11.81 in.).
(f) Tighten the 2 nuts.
Torque: 6.4 N
m (65 kgf
cm, 57 in.
lbf)
160. INSTALL EGR PIPE INSULATOR (See page 13 −12)
161. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
162. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
163. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
164. INSTALL OIL FILTER BRACKET SUB −ASSY
(a) Install a new gasket and the oil filter bracket with the bolt and 2 nuts.
Torque: 34 N
m (347 kgf
cm, 25 ft
lbf)
165. INSTALL V −RIBBED BELT TENSIONER BRACKET
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)