2005 TOYOTA AVENSIS water pump

A79148
SST
A79143
SST
±
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD±FTV)
14±333
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
43.REMOVE MANIFOLD STAY NO.2 (See page 13±11)
44.REMOVE MANIFOLD STAY (See page 13±11)
45.REMOVE EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
46.REMOVE TURBOCHARGER STAY (See page 13±11)
47.REMOVE TURBO WATER HOSE NO.1 (See page 13±11)
48.REMOVE TURBO WATER HOSE NO.2 (See page 13±11)
49.SEPARATE TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
50.REMOVE TURBOCHARGER SUB±ASSY (See page 13±11)
51.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
52.REMOVE CAMSHAFT TIMING PULLEY (See page 14±318)
SST 09960±10010 (09962±01000, 09963±01000)
53. REMOVE FUEL INLET PIPE SUB±ASSY
(a) Using SST, remove the fuel inlet pipe from the commonrail side.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023±12700
NOTICE:
After removing the fuel pipe, cover the common rail and the
injector mounting holes with vinyl tape to prevent dust
from being introduced.
54. REMOVE INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
SST 09023±12700
(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 a
plastic bag.
55. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
56. REMOVE INJECTION PIPE SUB±ASSY NO.3
SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.

A09609
A09680
SST
A09611
A09606
A09609
± ENGINE MECHANICALTIMING BELT (1CD±FTV)
14±309
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE TIMING BELT
HINT:
If re±use the timing belt, draw an arrow on the belt which indi-
cates the engine revolution direction and put match marks on
the pulleys and the belt before removing. This operation will be
very helpful when re±installing the timing belt.
(a) Alternately loosen the 2 bolts to remove the timing belt
tensioner.
(b) Remove the timing belt.
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, set the pulleys of the camshaft and the injec-
tion pump so that each timing mark of the pulleys is
aligned with its timing mark on the cylinder head assem-
bly and the water pump assembly.
SST 09960±10010 (09962±01000, 09963±01000)
(b) Using the crankshaft pulley bolt, align the dot mark of the
crankshaft timing pulley with the TDC mark of the oil pump
by turning the crankshaft.
NOTICE:
Take great care, when turning the camshaft and crank-
shaft. Since the valve head and the piston head are sensi-
tive, damage to them may result when the piston head con-
tacts with the valve heads.
22. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Remove any oil or water on each pulley and keep them
clean.
NOTICE:
Do not use any cleaning agent.

A09612
1st
2nd 5th
3rd
4th 6th 7th
A09589
Hexagon
Wrench
(1.27 mm)
(A)
A09623
A61179
Hexagon
Wrench
(1.27 mm)
A09605
Turn
Dot Mark
TDC Mark
14±310
± ENGINE MECHANICALTIMING BELT (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the timing belt in the following order:
1. Camshaft timing pulley
2. Supply pump drive pulley
3. Water pump pulley
4. Crankshaft timing pulley
5. No. 2 idler pulley
6. Oil pump pulley
7. No. 1 idler pulley
(c) Install the timing belt tensioner.
(1) Using a press, slowly press in the push rod with
pressure 981 to 9,807 N (100 to 1,000 kgf, 200 to
2,205 lbf).
(2) Align the holes of the push rod and the housing, in-
sert hexagon wrench (1.27 mm) through the holes
to keep the setting position of the push rod.
(3) Release the press.
(4) Temporarily install the tensioner with bolt (A).
(5) Turn the tensioner clockwise and temporarily install
the other bolt.
(6) Alternately tighten the 2 bolts.
Torque: 21 N´m (214 kgf´cm, 15 ft´lbf)
(7) Remove the hexagon wrench from the tensioner.
23. CHECK VALVE TIMING
(a) Slowly turn the crankshaft 2 complete revolutions (720
)
from TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.

A80118
A80115
A80116
A09660
14±292
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
80.REMOVE EGR PIPE SUB±ASSY NO.1
(a)Remove the bolt and 4 nut, and then detach the EGR pipe and the 2 gasket\
s. 81.REMOVE EXHAUST MANIFOLD
(a)Remove the 8 nuts, the exhaust manifold and the gasket.
82.REMOVE OIL COOLER ASSY (See page 17±32)
83. REMOVE WATER OUTLET SUB±ASSY 84. REMOVE INTAKE AIR CONNECTOR SUB±ASSY
(a) Remove the bolt and 2 nuts, and then remove the intakeair connector and the gasket.
85. REMOVE EGR VALVE ASSY
(a) Remove the bolt and 2 nuts, and then remove the EGR valve and the gasket.
86. REMOVE VACUUM PUMP ASSY
(a) Remove the 2 bolts, the vacuum pump and the 2 O±rings.

A79150
A61175
A09671
14±294
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
93.REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a)Remove the 2 bolts and the intake manifold insulator.
94.REMOVE COMMON RAIL ASSY (See page 11±78) 95.REMOVE POWER STEERING IDLE PULLEY
BRACKET
(a)Remove the 3 bolts and the idle pulley bracket.
96.REMOVE INTAKE MANIFOLD
(a)Remove the 2 bolts and the wiring harness clamp bracket.
(b)Remove the 8 bolts and 2 nuts, and then remove the in- take manifold and the gasket.
97.REMOVE INJECTION PUMP DRIVE PULLEY (See page 11±69) SST 09960±10010 (09962±01000, 09963±01000)
98. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, and then remove the timing belt c\
over.
99.REMOVE OIL LEVEL GAGE GUIDE (See page 17±22)
100.REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11±69)
101. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
(a) Remove the 4 bolts and the compressor mounting bracket.
102. REMOVE WATER INLET
(a) Remove the 2 bolts and the water inlet.
103. REMOVE THERMOSTAT
104. REMOVE OIL COOLER PIPE
(a) Remove the union bolt, the oil cooler pipe and the gasket.
105. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and nut, and then detach the fuel pipe.

A79173New O±Ring
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±295
AVENSIS REPAIR MANUAL (RM1018E)
106.REMOVE CRANKSHAFT POSITION SENSOR
(a)Remove the bolt and the crankshaft position sensor.
107.REMOVE CAMSHAFT POSITION SENSOR
(a)Remove the bolt and the camshaft position sensor.
108.REMOVE ENGINE COOLANT TEMPERATURE SENSOR
109.REPLACE PARTIAL ENGINE ASSY
110.INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Torque: 20 N
m (204 kgf
cm,15 ft
lbf)
111.INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
112.INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm,78 in.
lbf)
113.INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE Torque:
8.8 N
m (90 kgf
cm,78 ft
lbf) for M6 and Nut
21 N
m (209 kgf
cm,15 ft
lbf) for M8
114.INSTALL OIL COOLER PIPE
(a)Install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 59 N
m (600 kgf
cm,43 ft
lbf)
115.INSTALL THERMOSTAT (See page 16±50)
116.INSTALL WATER INLET (See page 16±50)
117. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
118. INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
119. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O±ring to the oil level gage guide.
(b) Apply engine oil to the O±ring.
(c) Push in the oil level gage guide end into the guide hole of the No. 1 oil pan.
(d) Install the oil level gage guide with the bolt. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
(e) Apply engine oil to the O±ring on the oil level gage.
(f) Install the oil level gage.
120. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
121.INSTALL INJECTION PUMP DRIVE PULLEY (See page 11±69)
SST 09960±10010 (09962±01000, 09963±01000)
122. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 8 bolts and 2 nuts\
. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(b) Install the wiring harness clamp bracket with the 2 bolts.
Torque: 3.9 to 6.9 N
m (40 to 70 kgf
cm, 35 to 61 in.
lbf)

A79196
New O±Ring
New O±Ring
A79182
Collar
Groove
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±299
AVENSIS REPAIR MANUAL (RM1018E)
132.INSTALL VACUUM PUMP ASSY
(a)Install 2 new O±rings to the vacuum pump.
(b)Align the key of the vacuum pump with the keyway of the
exhaust camshaft, insert the vacuum pump into place.
Secure the pump with the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
133.INSTALL EGR VALVE ASSY
(a)Install a new gasket and the EGR valve with the bolt and 2 nuts. Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
134.INSTALL INTAKE AIR CONNECTOR SUB±ASSY
(a)Install a new gasket and the intake air connector with diesel throttle b\
ody with the bolt and 2 nuts. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
135.INSTALL WATER OUTLET SUB±ASSY
(a)Install a new gasket and the water outlet with the 2 bolts. Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
136.INSTALL OIL COOLER ASSY (See page 17±32)
137.INSTALL EXHAUST MANIFOLD
(a)Install a new gasket, the exhaust manifold and the 8 col-lars with new 8 nuts.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
HINT:
When installing the collars, pay attention to the mounting
orientation. Ring groove of the collar should be outside. Refer
to the illustration on the left.
138.INSTALL EGR PIPE SUB±ASSY NO.1
(a)Install 2 new gaskets and the EGR pipe with the bolt and 4 new nuts. Torque:
37 N
m (375 kgf
cm,27 ft
lbf) for bolt
25 N
m (250 kgf
cm,18 ft
lbf) for nut
139.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
140.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
141.INSTALL TURBOCHARGER STAY (See page 13±11)
142.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
143.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
144.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
145.INSTALL TURBO INSULATOR NO.1 (See page 13±11)
146.INSTALL TURBO INSULATOR NO.2 (See page 13±11)

Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn 16±16
± COOLINGCOOLING SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push / 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
93 to 122 kPa (0.95 to 1.25 kgf/cm
2, 13.4 to 17.6 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.2 psi)
If the opening pressure is less than minimum, replace the radia-
tor cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.