2005 TOYOTA AVENSIS fuel

−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)11 −69
AVENSIS Supplement (RM1045E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST 09023 −12700
Torque:
For used pipe:
36 N
m (372 kgf
cm, 27 ft
lbf) with SST
40 N
m (408 kgf
cm, 30 ft
lbf) without SST
For new pipe:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
17. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
18. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
19. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
20. INSTALL FUEL PIPE NO.3 (See page 11 −46)
SST 09023 −12700

A87960
30 cm
(11.81 in.)
SST
11−70−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
21. INSTALL FUEL INLET PIPE SUB −ASSY
NOTICE:
S In case of replacing the common rail, the fuel inlet
pipe must be replaced, too.
S When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could 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:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
22. INSTALL RADIATOR RESERVE TANK SUB −ASSY (See Pub. No. RM1018E on page 16 −50)
23. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
24. ADD ENGINE COOLANT (See page 16 −19)
25. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
26. CHECK FOR FUEL LEAKS (See page 11 −46)

110UB−02
A85743
8.0 (82, 71 in.
lbf)
Engine Cover Sub−assy No. 1Radiator Support Opening Cover
N·m (kgf·cm, ft·lbf)
: Specified torque
6.0 (61, 53 in.
lbf)
Radiator Reserve
Tank Assy
Clip
Ratainer
x5
− FUELCOMMON RAIL ASSY (1CD−FTV)(From September,
2003)11−65
AVENSIS Supplement (RM1045E)
COMMON RAIL ASSY (1CD−FTV)(From September, 2003)
COMPONENTS

A85744
5.0 (51, 44 in.
lbf)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2zInjection Pipe Sub−assy
* 31 (316, 23)
34 (347, 25)
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
* Use SST
Common Rail Assy
Intake Manifold
Insulator No. 1
Fuel Hose No. 4
zFuel Inlet Pipe Sub−assy
5.0 (51, 44 in.
lbf)
43 (438, 32)
* 31 (316, 23)
34 (347, 25)
27 (275, 20)
Fuel Pipe No. 3
zGasket
5.0 (51, 44 in.
lbf)
x2
5.0 (51, 44 in.
lbf)
* 22 (223, 16)
24 (240, 17)
11−66− FUELCOMMON RAIL ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)

110U9−02
A85741
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
7.0 (71, 62 in.
lbf)
N·m (kgf·cm, ft·lbf)
: Specified torque
Radiator Hose Outlet
Clip
Engine Room Cover Side
Clip
Retainer
Radiator Support
Opening Cover
8.0 (82, 71 in.
lbf)
5.5 (56, 49 in.
lbf)
V (Cooler Compressor
to Crankshaft Pulley)
Belt No. 1
Injector Driver
72 (734, 53)
52 (530, 38)52 (530, 38)
Engine Cover
Sub−assy No. 1
Engine Mounting Insulator Sub−assy RH
39 (398, 29)
Power Steering
Idle Pulley Bracket
52 (530, 38)
Clip
Engine Under Cover RH
Engine Under Cover Sub−assy No. 1
Clip
Radiator Reserve Tank Assy
6.0 (61, 53 in.
lbf)
x5
x3
Exhaust Gas Temperature
Sensor Connector
Vacuum Hose
Mass Air Flow Meter
Connector
− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)11−55
AVENSIS Supplement (RM1045E)
INJECTION OR SUPPLY PUMP ASSY (1CD−FTV)(From
September, 2003)
COMPONENTS

A85610
: Specified torqueN·m (kgf·cm, ft·lbf)
* Replace only if damagedTiming Belt No. 2 Cover
Transverse Engine
Engine Mounting Bracket
Seal Washer Timing Belt No. 1 Cover
Crankshaft Pulley Seal Washer
x5 Generator V belt
Glow Plug
Screw Grommet Timing Belt GuideTiming Belt * Gasket
x7
Glow Plug Assy * Gasket Timing Chain Cover Plate
Timing Belt
Tensioner
180 (1,835, 133)
21 (214, 16)
9.0 (92, 80 in.·lbf)
37 (375, 27)
64 (650, 47)
2.2 (22, 19 in.·lbf)
7.4 (75, 65 in.·lbf)
7.4 (75, 65 in.·lbf)
Idler Pulley
40 (408, 30)Glow Plug
No. 1 Connector
11−56− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)

A85742
5.0 (51, 44 in.
lbf)
* 36 (372, 27)
40 (408, 30)
* 31 (316, 23)
34 (347, 25)
* 31 (316, 23)
34 (347, 25)
Injection Pipe Clamp No. 2
Injection Pipe Sub−assy
zFuel Inlet Pipe Sub−assy
64 (653, 47)
Injection Pump
Drive Pulley
zO−ring Oil Level Gage Guide
: Specified torqueN·m (kgf·cm, ft·lbf)
* Use SST
18 (184, 13)
Oil Level Gage Sub−assy Injection or
Supply Pump Assy
21 (209, 15)
21 (209, 15)
Water Inlet
8.8 (90, 78 in.
lbf)
zGasket
5.0 (51, 44 in.
lbf)
Intake Manifold Insulator No. 1
Injection Pump to Fuel Filter
Fuel Hose or Pipe
Injection Pump to Fuel Pipe
Fuel Hose
Fuel Pipe No. 3
zGasket
27 (275, 20)
5.0 (51, 44 in.
lbf)
x3
zNon−reusable part
5.0 (51, 44 in.
lbf)
* 22 (223, 16)
24 (240, 17)
* 31 (316, 23)
34 (347, 25)
− FUELINJECTION OR SUPPLY PUMP
ASSY (1CD−FTV)(From September, 2003)11−57
AVENSIS Supplement (RM1045E)

1111 D−01
A93661
(a)
(a)
(b)(b)
(a)
(a)
A85630
11−46
− FUELINJECTOR ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
NOTICE:
If an incorrect injector compensation code was registered with the ECM, it may rattle the engine as-
sembly or the engine idling may become rough. In addition, it may become a cause of engine failure
or shorten the life of the engine.
HINT:
SIn order to optimize the injector’s fuel injection characteristic, the ECM compensates the injection dura-
tion by each cylinder. The ECM stores and uses compensating data in the form of a 30−digit−alphanu-
meric value that is imprinted on the head portion of each injector as the injector compensation code.
SIf you installed a new injector, its own injector compensation code is needed to register with the ECM.
Also, if you replaced the ECM, the compensation codes of all the injectors are needed to register be-
cause the new ECM does not have the codes until they are registered.
SOnce the ECM is replaced, DTC P1601 will be present when turning the ignition switch to ON. This
is to inform you that the injector compensation codes are required to register with the ECM. In order
to clear the DTC, register the compensation codes first, then turn the ignition switch to OFF and wait
for 30 seconds or longer.
1. REMOVE VACUUM RESERVOIR SUB−ASSY
(a) Disconnect the 2 vacuum hoses and connector.
(b) Remove the 2 bolts and vacuum reservoir.
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER SUB−ASSY NO.1
(a) Remove the 5 nuts and engine cover.
4. REMOVE AIR CLEANER ASSY
(a) Disconnect the connector.
(b) Remove the air cleaner cap together with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and air cleaner case.
5. REMOVE AIR TUBE NO.1
(a) Remove the 3 bolts and nut, then separate the air tube
No. 1.
(b) Loosen the hose clamp bolts.
6. REMOVE FUEL PIPE NO.3
(a) Remove the fuel pipe insulator.