2005 TOYOTA AVENSIS fuel

A64328
2 to 7 mm0 to 2 mm
A78274
Upward
90

Clamp
Bolt
A64328
2 to 7 mm 0 to 4 mm
A64007
Front
90

Clamp
Bolt
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1CD±FTV)
14±303
AVENSIS REPAIR MANUAL (RM1018E)
184.INSTALL AIR TUBE NO.1
(a)Install the new air hose No. 1 and new hose clamp as
shown in the illustration.
(b)Tighten the hose clamp as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
185.INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
186.CONNECT ENGINE WIRE Torque: 8.4 N
m (85 kgf
cm,74 in.
lbf)
187.INSTALL AIR TUBE NO.2
(a)Install the air hose and hose clamps as shown in the il- lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm,53 ft
lbf)
(c)Install the 2 bolts and the air tube No.2 assy.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
188.INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
189. INSTALL ENGINE ROOM RELAY BLOCK NO.3 Torque: 5.3 N
m (54 kgf
cm, 46 in.
lbf)
190. INSTALL FUEL FILTER ASSY Torque: 18 N
m (178 kgf
cm, 13 ft
lbf)

14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)

17045±03
A56466
Recommended Viscosity (SAE)
BEFORE NEXT OIL CHANGE TEMPERATURE RANGE ANTICiPATED416 2738
0 20 40 60 80 100 ±29
±20±18 ±7
C

F20 W ± 50
15 W ± 40
10 W ± 30
5 W ± 30 PREFERRED
B14332
Oil Pressure Switch
B14333
Oil Pressure Gauge 17±20
± LUBRICATIONLUBRICATION SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) After warm up the engine and then 5 minutes after the engine stop, oil level should be between the
low level and full level marks of the dipstick.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, entry of water, discoloring
or thinning.
If the quality is visibly poor, replace the oil.
Oil grade:
Use ACEA B1, API grade CF ± 4 or CF
(You may also use API CE or CD)
SAE 5W ± 30 is the best choice for your vehicle, for
good fuel economy, and good starting in cold weath-
er.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24mm, remove the oil pres-
sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE

170FX±01
A77339
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)

17±18
±
LUBRICATION OIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
64.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
65.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
66.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
67.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
68.INSTALL VANE PUMP ASSY Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
69.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
70.INSTALL GENERATOR ASSY (See page 19±20)
71.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
72.INSTALL FUEL PUMP ASSY (See page 11±52)
73.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
74.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
75.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
76. ADD ENGINE OIL
77. CHECK FOR ENGINE OIL LEAKS
78. CHECK FUEL LEAK
79. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
80. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

170FU±01
A77281
17±8
±
LUBRICATION OIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
10.REMOVE GENERATOR ASSY (See page 19±20)
11.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
12.SEPARATE VANE PUMP ASSY (See page 14±139)
13.SEPARATE RETURN TUBE SUB±ASSY (See page 14±139)
14. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) (See page 14±139)
15. SEPARATE VANE PUMP OIL RESERVOIR ASSY
16.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±139)
17. SEPARATE ENGINE WIRE
18. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove a bolt and the engine service cover bracket RH.
19.REMOVE COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE\
) (See
page 14±139)
20. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
21. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
22.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
23.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
24.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)

160ME±01
A79148
SST
16±46
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)

A79148
SST
A79149
SST
16±48
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
39.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69) 40. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the water pump replaced, must re-
place fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the new fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe to the injec- tion pump side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.