TOYOTA AVENSIS 2005 Service Repair Manual

B66534
B66535
Clip
B66527
Clip
±
EXTERIOR/INTERIOR TRIM ROOF HEADLINING ASSY(WAGON MODELS)
76±55
AVENSIS REPAIR MANUAL (RM1018E)
7.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
8.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
9.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
10.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
11.REMOVE CENTER PILLAR GARNISH LOWER RH
(a)Remove the floor anchor cover.
(b)Remove the bolt and outer belt on the floor anchor side.
(c)Using a screwdriver, disengage the 2 clips and removethe pillar garnish.
HINT:
Tape the screwdriver tip before use.
12.REMOVE CENTER PILLAR GARNISH LOWER LH
HINT:
Use the same procedures described for the RH side. 13.REMOVE CENTER PILLAR GARNISH UPPER RH
(a)Using a screwdriver, disengage the clip and 2 screws, andremove the pillar garnish.
HINT:
Tape the screwdriver tip before use.
14.REMOVE CENTER PILLAR GARNISH UPPER LH
HINT:
Use the same procedures described for the RH side.
15.REMOVE REAR SEAT ASSY (See page 72±21)
16. REMOVE REAR SIDE SEAT BACK ASSY RH
(a) Remove the bolt and seatback
17. REMOVE REAR SIDE SEAT BACK ASSY LH
(a) Remove the bolt and seatback
18. REMOVE TONNEAU COVER ASSY
19. REMOVE BACK DOOR WEATHERSTRIP

B66545
B66544
Clip
B66543
B66542
Clip
76±56
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE DECK BOARD SUB±ASSY
21. REMOVE DECK FLOOR BOX REAR
(a) Remove the deck floor box.
22. REMOVE DECK FLOOR BOX FRONT
(a) Using a screwdriver, disengage the 2 clips and 2 screws,
and remove the deck floor box.
HINT:
Tape the screwdriver tip before use.
23. REMOVE DECK FLOOR BOX RH
(a) Remove the 2 screws and deck floor box.
24. REMOVE DECK FLOOR BOX LH
(a) Remove the 2 screws and deck floor box.
25. REMOVE REAR FLOOR FINISH PLATE
(a) Using a screwdriver, disengage the 4 clips and remove
the floor finish plate.
HINT:
Tape the screwdriver tip before use.

B66536
Clip
Claw
B66540
Clip
B66538
Clip
B66539
Clip
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
76±57
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE DECK TRIM SIDE BOARD RH
(a) Remove the bolt and screw.
(b) Using a screwdriver, disengage the 5 clips and 2 claws,
and remove the deck trim side board.
HINT:
Tape the screwdriver tip before use.
27. REMOVE DECK TRIM SIDE BOARD LH
HINT:
Use the same procedures described for the RH side.
28. REMOVE ROOF HEADLINING TRIM SUB±ASSY
REAR
(a) Using a screwdriver, disengage the 5 clips and remove
the roof headlining trim.
HINT:
Tape the screwdriver tip before use.
29. REMOVE ROOF SIDE GARNISH INNER RH
(a) Remove the bolt.
(b) Using a screwdriver, disengage the 2 clips and remove
the window side garnish.
HINT:
Tape the screwdriver tip before use.
30. REMOVE ROOF SIDE GARNISH INNER LH
HINT:
Use the same procedures described for the RH side.
31. REMOVE REAR WINDOW SIDE GARNISH RH
(a) Using a screwdriver, disengage the 3 clips and screw, and
remove the roof side garnish.
HINT:
Tape the screwdriver tip before use.

B66528
Clip
B65292
700 mm120 mm
Adhesive Tape
Adhesive Tape
Protective Cover
76±58
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
32. REMOVE REAR WINDOW SIDE GARNISH LH
HINT:
Use the same procedures described for the RH side.
33. REMOVE FRONT PILLAR GARNISH RH
(a) Using a screwdriver, disengage the 2 clips and remove
the pillar garnish.
HINT:
Tape the screwdriver tip before use.
(b) Pull the garnish upward and remove if from the instrument
panel.
(c) w/ Curtain shield airbag:
Protect the curtain shield airbag LH.
(1) Thoroughly cover the airbag with cloth or nylon of
700 mm (27.56 in.) x 120 mm (4.72 in.) and fix the
ends of the cover in place with adhesive tape as
shown in the illustration.
NOTICE:
Cover the curtain shield airbag with a protective cover as
soon as the front pillar garnish is removed.
34. REMOVE FRONT PILLAR GARNISH LH
HINT:
Use the same procedures described for the RH side.
35. REMOVE RH VISOR ASSY
(a) Remove the 2 screws and visor.
36. REMOVE LH VISOR ASSY
(a) Remove the 2 screws and visor.

A79919
Claw
Claw
B66541Claw
Claw
B66529
ClawClaw
B50596
90

± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
76±59
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE MAP LAMP ASSY
(a) Using a screwdriver, disengage the 6 claws and remove
the lens cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 screws.
(c) Using a moulding remover, disengage the claws.
(d) Disconnect the map lamp switch connector and sliding
roof switch connector, and remove the map lamp.
38. REMOVE ROOM LAMP ASSY NO.2
(a) Using a moulding remover, disengage the 8 claws and re-
move the lens cover.
HINT:
Tape the screwdriver tip before use.
(b) Using a moulding remover, disengage the claws.
(c) Disconnect the map lamp switch connector and remove
the map lamp.
39. REMOVE ASSIST GRIP SUB±ASSY
(a) Using a screwdriver, disengage the 2 claws and remove
the 2 assist grip covers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 bolts and assist grip.
40. REMOVE VISOR HOLDER
(a) Remove the holder of the sun visor by turning it counter-
clockwise.
41. REMOVE SUN ROOF OPENING TRIM MOULDING (W/ SLIDING ROOF)

B66558
Clip
w/ Sliding Roof
w/o Sliding RoofClip
B66555
Tape
w/ Sliding Roof
w/o Sliding Roof
Tape
76±60
±
EXTERIOR/INTERIOR TRIM ROOF HEADLINING ASSY(WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE ROOF HEADLINING ASSY
(a)w/ Sliding roof: Using a clip remover, disengage the 2 clips and remove
the roof headling.
(b)w/o Sliding roof: Using a clip remover, disengage the 4 clips and remove
the roof headling.
43.INSTALL ROOF HEADLINING ASSY
(a)Align the markings, and then install the wire harness with tape.
NOTICE:
Attach the roof wire harness securely.
(b)w/ Sliding roof: Install the 4 clips.
(c)wo/ Sliding roof: Install the 2 clips.
44.INSTALL REAR SEAT ASSY (See page 72±21)

031FL±01
± SERVICE SPECIFICATIONSLUBRICATION
03±9
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Oil pump x Oil pump cover8.89080 in.
lbf
Oil pump x Oil pump relief valve plug4950035

022KC±01
± PREPARATIONSTARTING & CHARGING
02±5
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
STARTING & CHARGING
PREPARATION
SST
09285±76010Injection Pump Camshaft Bearing
Cone ReplacerGENERATOR ASSY
Recomended Tools
09041±00020Torx Driver T25STARTER ASSY
09904±00010Expander SetSTARTER ASSY
(09904±00050)No. 4 ClawSTARTER ASSY
Equipment
Dial indicator
Ohmmeter
Torque wrench
Slide calipers
V±block

010BA±12
01±12
± INTRODUCTIONTERMS
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI/INJ)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

± INTRODUCTIONTERMS
01±13
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter