TOYOTA AVENSIS 2005 Service Repair Manual

03±14
± SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
New drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf)
For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
Used drive belt deflection Pressing force: 98 N (10 kgf, 22 lbf)
For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
9.5 to 11.5 mm (0.37 to 0.45 in.)
10 to 12 mm (0.39 to 0.47 in.)
12.5 to 15.5 mm (0.49 to 0.61 in.)
14 to 17 mm (0.55 to 0.67 in.)
New drive belt tension
For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
Used drive belt tension
For vane pump V belt (A/C equipped)
For vane pump V belt (A/C not equipped)
519 to 755 N (53 to 77 kgf, 117 to 170 lbf)
686 to 784 N (70 to 80 kgf, 154 to 176 lbf)
196 to 392 N (20 to 40 kgf, 44 to 88 lbf)
294 to 441 N (30 to 45 kgf, 66 to 99 lbf)
Idle speed750 to 850 rpm.
Maximum speed5,100 to 5,250 rpm.
Compression pressure
at 250 rpm.
Minimum
Difference between each cylinder
2,628 kPa (26.8 kgf/cm2, 381 psi) or more
2,157 kPa (22.0 kgf/cm2, 312 psi) or more
490 kPa (5.0 kgf/cm2, 71 psi) or less
Cylinder head set bolt
Outside diameter Standard
Minimum
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
10.40 mm (0.4904 in.)
Valve clearance
Intake (cold)
Exhaust
Adjusting shim thickness Mark 2.500
Mark 2.550
Mark 2.600
Mark 2.650
Mark 2.700
Mark 2.750
Mark 2.800
Mark 2.850
Mark 2.900
Mark 2.950
Mark 3.000
Mark 3.050
Mark 3.100
Mark 3.150
Mark 3.200
Mark 3.250
Mark 3.300
0.20 to 0.30 mm (0.008 to 0.012 in.)
0.35 to 0.45 mm (0.014 to 0.018 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Cylinder head set bolt
Outside diameter Standard
Minimum
10.75 to 11.00 mm (0.4232 to 0.4331 in.)
10.40 mm (0.4904 in.)

031FR±02
03±12
± SERVICE SPECIFICATIONSINTAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Turbo water pipe sub±assy No.1 x Turbocharger sub±assy131359.7
Turbocharger sub±assy x Exhaust manifold5354039
Turbo oil outlet pipe x Turbocharger sub±assy131359.7
Manifold converter sub±assy x Turbocharger sub±assy 1st
2nd8.0
2582
25571 in.
lbf
18
Manifold stay x Manifold converter sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Manifold stay x Cylinder block sub±assy 1st
2nd8.0
6182
62271 in.
lbf
45
Turbohcharger stay x Turbocharger sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Turbocharger stay x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Manifold converter sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Manifold stay No. 2 x Cylinder head sub±assy 1st
2nd8.0
5682
57171 in.
lbf
41
Exhaust manifold heat insulator No. 2 x Turbocharger sub±assy121228.9
Turbo insulator No. 1 x Manifold converter sub±assy2020415
Turbo insulator No. 1 x Turbocharger sub±assy2020415
Turbo insulator No. 2 x Manifold converter sub±assy2020415
Exhaust pipe assy x Heater bracket sub±assy w/ Cold area7.57666 in.
lbf
Exhaust pipe assy x Body w/ Cold area7.57666 in.
lbf
Heater bracket x Body w/ Cold area7.57666 in.
lbf
Heater pump assy x Heater bracket w/ Cold area7.57666 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 cover2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Air cleaner case x Body7.07162 in.
lbf
Intercooler assy x Body7.07162 in.
lbf
Intercooler cooling air duct x Intercooler assy5.05144 in.
lbf
Air cleaner case x Engine mounting insulator LH7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38573 in.
lbf

031FQ±01
± SERVICE SPECIFICATIONSINTAKE
03±11
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE
SERVICE DATA
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
33 to 39

1CD±FTV:
Turbocharging pressure
Standard pressure
15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.2 to 6.5 psi)
Turbo pressure sensor
Voltage 3 (VC) ± 1 (E2)
Voltage drop apply vacuum 13.3 kPa (100 mmHg, 3.94 in.Hg)
apply vacuum 26.7 kPa (200 mmHg, 7.87 in.Hg)
apply vacuum 40.0 kPa (300 mmHg, 11.81 in.Hg)
apply vacuum 57.3 kPa (400 mmHg, 15.75 in.Hg)
apply vacuum 66.7 kPa (500 mmHg, 19.96 in.Hg)
Voltage up applied vacuum 19.6 kPa (0.20 kgf/cm2, 2.84 psi)
applied vacuum 39.2 kPa (0.40 kgf/cm2, 5.69psi)
applied vacuum 58.8 kPa (0.60 kgf/cm2, 8.53psi)
applied vacuum 78.5 kPa (0.80 kgf/cm2, 11.4psi)
applied vacuum 98.0 kPa (1.00 kgf/cm2, 14.2psi)
4.5 to 5.5 V
0.1 to 0.3 V
0.3 to 0.5 V
0.5 to 0.7 V
0. 7 to 0.9 V
0. 9 to 1.0 V
0.1 to 0.4 V
0.4 to 0.7 V
0.7 to 1.0 V
1.0 to 1.3 V
1.3 to 1.6 V

031FP±01
03±10
± SERVICE SPECIFICATIONSEMISSION CONTROL
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Heated oxygen sensor
Resistance Bank 1 sensor 1
1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10 at 20
C (68
F)
No continuity
Heated oxygen sensor
Resistance Bank 1 sensor 2
1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10 at 20
C (68
F)
No continuity
Vacuum switching valve
Resistance at 20
C (68
F)
26 to 30 
1AZ±FE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
26 to 30 
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16  at 20
C (68
F)
No continuity
Air fuel ratio sensor
Resistance 1 (HT) ± 2 (+B)
1 (HT) ± 2 (+B)
1 (HT) ± 4 (E1)
1.8 to 3.4 at 20
C (68
F)
5.0 to 7.5 at 500
C (932
F)
No continuity
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
26 to 30 
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16  at 20
C (68
F)
No continuity
1CD±FTV:
EGR valve assy
Resistance +B1 ± EGR1
+B1 ± EGR2
+B1 ± EGR3
+B1 ± EGR4
19.6
1.4 at 20
C (68
F)
19.6
1.4 at 20
C (68
F)
19.6
1.4 at 20
C (68
F)
19.6
1.4 at 20
C (68
F)
Vacuum switching valve assy
Resistance at 20
C (68
F)
10 to 14 

031E1±02
03±8
± SERVICE SPECIFICATIONSFUEL
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy Bolt A
Bolt B19
9.0194
9214
80 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Fuel delivery pipe sub±assy x Cylinder head sub±assy2020415
Fuel pressure pulsation damper assy x Fuel delivery pipe sub±assy9.09280 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Cylinder head cover x Fuel pump assy2525518
Fuel pipe sub±assy No.1 x Fuel delivery pipe sub±assy9.09280 in.
lbf
Fuel pipe sub±assy No.1 x Fuel pump assy3030622
Fuel pressure pulsation damper assy x Fuel pump assy3333124
Engine cover bracket x Cylinder head3838828
Engine cover sub±assy No.1 x Cylinder head cover7.07162 in.
lbf
Nozzle holder clamp x Cylinder head131279
Fuel delivery pipe sub±assy x Cylinder head1919414
Surge tank stay No.1 x Cylinder block2121015
Intake manifold x Cylinder head Stud bolt
Bolt
Nut9.5
30
3097
306
30684 in.
lbf
22
22
GASOLINE:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy No. 1 LH x Body4040029
Fuel tank band sub±assy No. 1 RH x Body4040029
Parking brake cable assy No. 3 x Body5.05144 in.
lbf
Parking brake cable assy No. 2 x Body5.05144 in.
lbf
Fuel tank protector No. 1 x Body5.45447 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 1 RH5.45447 in.
lbf
Exhaust pipe assy front x Exhaust manifold (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy front x Exhaust pipe assy tail (1ZZ±FE/3ZZ±FE)4344033
Exhaust pipe assy center x Exhaust pipe assy front (1AZ±FE/1AZ±FSE)4344033
Exhaust pipe assy center x Exhaust pipe assy tail (1AZ±FE/1AZ±FSE)4344033
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Nozzle holder clamp x Cylinder head sub±assy2626519
Nozzle leakage pipe assy x Injector assy Hollow screw
Union bolt18
22184
22413
16
Nozzle leakage pipe No. 2 x Cylinder head sub±assy Hollow screw
Bolt21
8.8214
9016
79 in.
lbf
Injection pipe sub±assy No. 1 ± No. 4 x Injector assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe sub±assy No. 1 ± No. 4 x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25

± SERVICE SPECIFICATIONSFUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf

031E0±01
± SERVICE SPECIFICATIONSFUEL
03±7
AVENSIS REPAIR MANUAL (RM1018E)
FUEL
SERVICE DATA
GASOLINE:
Compression spring
Free length Minimum Front x Manifold (1ZZ±FE/3ZZ±FE)
Front x Tail (1ZZ±FE/3ZZ±FE)
Center x Tail (1AZ±FE/1AZ±FSE)
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
38.5 mm (1.516 in.)

031DZ±02
03±6
± SERVICE SPECIFICATIONSENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle position sensor x Throttle body assy2.02018 in.
lbf
ISC valve x Throttle body assy3.73833 in.
lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold9.09280 in.
lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.
lbf
Wire harness protector x Throttle body bracket8.48674 in.
lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Accelerator pedal x Body5.45548 in.
lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.
lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.
lbf
Crankshaft position sensor x Oil pump assy8.89079 in.
lbf
ECM x Body5.55649 in.
lbf

031DY±01
03±4
± SERVICE SPECIFICATIONSENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE CONTROL SYSTEM
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Power steering oil pressure switch
Voltage EMPS ± E2
Not spin the steering wheel at engine idling
Spin the steering wheel at engine idling
8 to 14 V
0 to 1.5 V
Idle air control valve
Movement Ignition switch ON
Half open fully close  fully open half open
Mass air flow meter
Resistance 4 (THA) ± 5 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
13.6 to 18.4 k

2.21 to .69 k

0.49 to 0.67 k

Camshaft timing oil control valve assy
Resistance at 20
C (68
F)
6.9 to 7.9

Throttle position sensor
Resistance VC ± E2
2.5 to 6.0 k

E.F.I. Engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k

0.310 to 0.326 k

Knock control sensor
Resistance Approx. 20
C (68
F)
120 to 280 k

1AZ±FE/1AZ±FSE:
Power steering oil pressure switch
Voltage PSW ± E2
Not spin the steering wheel at engine idling
Spin the steering wheel at engine idling
9 to 14 V
0 to 3 V
Idle air control valve
Movement Ignition switch ON
Half open fully close  fully open half open
Throttle body assy (1AZ±FSE)
Throttle valve opening percentage
Idle speed
60 % or more
700 50 rpm
Accelerator pedal position sensor (1AZ±FSE)
Voltage ACCEL POS Released
Depress
ACCEL POS #2 Released
Depress
0.5 to 1.1 V
2.6 to 4.5 V
1.2 to 2.0 V
3.4 to 5.3 V
Mass air flow meter
Resistance 4 (THA) ± 5 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
13.6 to 18.4 k

2.21 to .69 k

0.49 to 0.67 k

Camshaft timing oil control valve assy
Resistance at 20
C (68
F)
6.9 to 7.9

Throttle position sensor (1AZ±FE)
Resistance VC ± E2
2.5 to 5.0 k

Throttle body assy (1AZ±FSE)
Resistance 2 (M+) ± 1 (M±)
0.3 to 100
at 20
C (68
F)
E.F.I. Engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k

0.310 to 0.326 k

Knock control sensor
Resistance Approx. 20
C (68
F)
120 to 280 k

±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
03±5
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
Mass air flow meter
Resistance2 (THA) ± 1 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
12.5 to 16.9 k 
2.19 to 2.67 k 
0.50 to 0.68 k 
Intake shutter assy
Resistanceat 20
C (68
F)
2 ± 1, 3
5 ± 4, 6
18 to 22 
18 to 22 
Accelerator pedal assy (See page 10±56)
Resistance VPA1 ± EP1
VPA2 ± EP2
VCP1 ± EP1
VCP2 ± EP2
5.0 k or less
5.0 k or less
1.5 to 6.0 k 
1.5 to 6.0 k 
Diesel turbo inlet air temperature sensor
Resistance Approx. 20
C (68
F)
2.21 to 2.65 k 
Crankshaft position sensor
Resistance at cold
at hot
1630 to 2740 
2065 to 3225 
Camshaft position sensor
Resistance at cold
at hot
1630 to 2740 
2065 to 3225 
Diesel engine engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k 
0.310 to 0.326 k 
Injection or supply pump assy
Resistance THF ± E2
Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.21 to 2.69 k 
0.287 to 0.349 k