TOYOTA AVENSIS 2005 Service Repair Manual

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 5
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Engine cover No. 1 x Cylinder head cover9.09280 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90 _806
Turn 90 _58
Turn 90 _
Camshaft timing oil control valve assy x Cylinder head9.09279 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Battery carrier x Frame131319.5
Battery clamp x Body Bolt
Nut5.0
3.551
3644 in. lbf
31 in. lbf
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14 −45) Bolt A
Bolt B
Bolt C
Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1 CD −FTV:
Part TightenedN
mkgf
cmft
lbf
Air tube No. 1 hose clamp bolt6.06153 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 cover sub −assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub −assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020014
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5657542
Compressor mounting bracket x Cylinder block4242831
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf

03−1 6
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Intake manifold x Cylinder head2120915
Power steering idle pulley bracket x Cylinder head
(See page 14 −108) Bolt A
Bolt B
72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe x injection pump With SST
Without SST
31
34316
34723
25
Nozzle leakage pipe No.2 x Cylinder head cover sub −assy8.89078 in.
lbf
Nozzle leakage pipe No.2 x Cylinder head8.89078 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2120915
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub −assy x Cylinder head2120915
Exhaust manifold x Cylinder head4747434
EGR pipe sub −assy x Cylinder head Bolt
Nut37
25375
25027
18
Vacuum pump oil pipe x Cylinder block Bolt Nut21
8.8214 9015
78 in.
lbf
Vacuum transmitting pipe No. 2 x Manifold converter
For nut With SST
Without SST
For bolt
27
30
25275
306
25520
22
18
Vacuum transmitting pipe No. 1 x Manifold converter
For nut With SST Without SST
For bolt
27
30
25275
306
25520
22
18
Exhaust gas temperature sensor x Manifold converter With SST
Without SST27
30275
30620
22
Exhaust gas temperature sensor x Vacuum transmitting pipe No. 26.46557 in.
lbf
Oil filter bracket x Oil pan sub −assy3434725
V −ribbed belt tensioner bracket x Cylinder block2020415
V −ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub −assy x V −ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub −assy center x Body4545933

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 7
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Front suspension crossmember sub −assy x Rear engine mounting bracket8788764
Front suspension crossmember sub −assy x Front engine mounting bracket5253038
Front suspension crossmember sub −assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub −assy1331,35698
Front suspension member brace x Body8081659
Return tube sub −assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting blacket5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Air tube No. 2 hose clamp bolt Intake shutter side
Air hose No. 3 side6.0
5.361
5453 in.
lbf
47 in.
lbf
Injector driver x Engine mounting insulator RH5.55649 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay block x Radiator assy5.35447 in.
lbf
Differential pressure sensor x Body5.55649 in.
lbf
Air cleaner assy x Body x Engine mounting bracket LH7.07162 in.
lbf
Battery clamp x Body Body
Nut5.0
3.0 to 4.051
31 to 4144 in.
lbf
27 to 35 in.
lbf
Battery terminal5.45548 in.
lbf
Timing belt tensioner x Cylinder block2121415
Timing chain cover plate x Camshaft oil seal retainer9.09280 in.
lbf
Transverse engine engine mounting bracket x
Cylinder block (See page 14 −138) Bolt A
Bolt B
37
64375
65027
47
Timing belt No. 1 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 1 cover x Oil pump assy7.47565 in.
lbf
Timing belt No. 2 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 2 cover x Cylinder head cover sub −assy7.47565 in.
lbf
Timing belt No. 2 cover x Camshaft oil seal retainer7.47565 in.
lbf
Timing belt No. 2 cover x Timing belt cover No. 37.47565 in.
lbf
Crankshaft pulley x Crankshaft1801,835133
Camshaft bearing cap x Cylinder head2020415
Camshaft oil seal retainer x Cylinder head9.81007.2
Camshaft timing pulley x Camshaft8889965
Nozzle leakage pipe x Injector1616312
Nozzle leakage pipe x Camshaft bearing cap No. 42020415
Cylinder head cover x Cylinder head131359.7
Vacuum reservoir sub −assy x Cowl top panel outer8.38573 in.
lbf
Cylinder head x Cylinder block 1st
2nd3rd4th45
Turn 90 _
Turn 90 _
Turn 90 _459
Turn 90 _
Turn 90 _
Turn 90 _33
Turn 90 _
Turn 90 _
Turn 90 _
Exhaust fuel addition injector x Cylinder head1211 78.5
Drain plug (oil pan)3435025

023N8−01
− PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02−31
AVENSIS Supplement (RM1045E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09308−00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U151E)
09316−60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U151E)
(09316−00011)Replacer PipeFRONT DIFFERENTIAL OIL
SEAL(U151E)
09350−32014TOYOTA Automatic Transmission
Tool SetAUTOMATIC TRANSAXLE
ASSY(U151E)
(09351−32010)One−way Clutch Test ToolAUTOMATIC TRANSAXLE
ASSY(U151E)
(09351−32020)Stator StopperAUTOMATIC TRANSAXLE
ASSY(U151E)
09520−01010Drive Shaft Remover AttachmentAUTOMATIC TRANSAXLE
ASSY(U151E)
09520−24010Differential Side Gear Shaft
PullerAUTOMATIC TRANSAXLE
ASSY(U151E)
(09520−32040)Shocker SetAUTOMATIC TRANSAXLE
ASSY(U151E)
09628−62011Boll Joint PullerAUTOMATIC TRANSAXLE
ASSY(U151E)
09649−17010Steering Knuckle ToolFRONT DIFFERENTIAL OIL
SEAL(U151E)
09930−00010Drive Shaft Nut ChiselAUTOMATIC TRANSAXLE
ASSY(U151E)

02−32
− PREPARATIONAUTOMATIC TRANSMISSION / TRANS
AVENSIS Supplement (RM1045E)
09950−70010Handle SetFRONT DIFFERENTIAL OIL
SEAL(U151E)
(09951−07150)Handle150FRONT DIFFERENTIAL OIL
SEAL(U151E)
Recomended Tools
09011−12301Socket Wrench 30 mmAUTOMATIC TRANSAXLE
ASSY(U151E)
09040−00011Hexagon Wrench SetTRANSMISSION OIL
COOLER(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E)
TRANSMISSION WIRE(U151E)
TRANSMISSION VALVE BODY
ASSY(U151E)
FRONT DIFFERENTIAL OIL
SEAL(U151E)
(09043−20100)Socket Hexagon Wrench10TRANSMISSION OIL
COOLER(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E)
TRANSMISSION WIRE(U151E)
TRANSMISSION VALVE BODY
ASSY(U151E)
FRONT DIFFERENTIAL OIL
SEAL(U151E)
09090−04020Engine Sling DeviceAUTOMATIC TRANSAXLE
ASSY(U151E)
SSM
08833−00080Adhesive1344
THREE BOND1344
LOCTITE 242 or equivalentTRANSMISSION WIRE(U151E)
TRANSMISSION VALVE BODY
ASSY(U151E)
Equipment
Straight edge
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Slide calipers
Lubricant
U151E
Automatic transaxle fluid
Dry fill
Drain and refill
8.8 liter (9.3 USqts, 7.7 lmp.qts)
3.5 liter (3.7 USqts, 3.1lmp.qts)ATF type T−IV

022ZQ−01
02−30
− PREPARATIONBRAKE
AVENSIS Supplement (RM1045E)
BRAKE
PREPARATION
SST
09023−00100Union Nut Wrench10mmBRAKE BOOSTER ASSY(RHD)
(2AZ−FSE)
Equipment
Torque wrench

023BA−01
− PREPARATIONDRIVE SHAFT / PROPELLER SHAFT
02−27
AVENSIS Supplement (RM1045E)
DRIVE SHAFT / PROPELLER SHAFT
PREPARATION
SST
09240−00020Wire Gauge SetFRONT DRIVE SHAFT(2AZ−FSE)
09520−01010Drive Shaft Remover AttachmentFRONT DRIVE SHAFT(2AZ−FSE)
09520−24010Differential Side Gear Shaft
PullerFRONT DRIVE SHAFT(2AZ−FSE)
(09520−32040)Shocker SetFRONT DRIVE SHAFT(2AZ−FSE)
09521−24010Rear Axle Shaft PullerFRONT DRIVE SHAFT(2AZ−FSE)
09527−10011Rear Axle Shaft Bearing RemoverFRONT DRIVE SHAFT(2AZ−FSE)
09608−16042Front Hub Bearing Adjusting ToolFRONT DRIVE SHAFT(2AZ−FSE)
(09608−02021)Bolt & NutFRONT DRIVE SHAFT(2AZ−FSE)
(09608−02041)RetainerFRONT DRIVE SHAFT(2AZ−FSE)
09628−62011Boll Joint PullerFRONT DRIVE SHAFT(2AZ−FSE)
09710−04081BaseFRONT DRIVE SHAFT(2AZ−FSE)
09726−40010Lower Control Shaft Bearing
ReplacerFRONT DRIVE SHAFT(2AZ−FSE)

02−28
− PREPARATIONDRIVE SHAFT / PROPELLER SHAFT
AVENSIS Supplement (RM1045E)
09930−00010Drive Shaft Nut ChiselFRONT DRIVE SHAFT(2AZ−FSE)
09950−00020Bearing RemoverFRONT DRIVE SHAFT(2AZ−FSE)
09950−60020Replacer Set No.2FRONT DRIVE SHAFT(2AZ−FSE)
(09951−00710)Replacer 71FRONT DRIVE SHAFT(2AZ−FSE)
09950−70010Handle SetFRONT DRIVE SHAFT(2AZ−FSE)
(09951−07100)Handle100FRONT DRIVE SHAFT(2AZ−FSE)
Recomended Tools
09011−12301Socket Wrench 30 mmFRONT DRIVE SHAFT(2AZ−FSE)
09040−00011Hexagon Wrench SetFRONT DRIVE SHAFT(2AZ−FSE)
(09043−20060)Socket Hexagon Wrench 6FRONT DRIVE SHAFT(2AZ−FSE)
09904−00010Expander SetFRONT DRIVE SHAFT(2AZ−FSE)
(09904−00050)No. 4 ClawFRONT DRIVE SHAFT(2AZ−FSE)
09905−00012Snap Ring No.1ExpanderFRONT DRIVE SHAFT(2AZ−FSE)
(09043−20060)Socket Hexagon Wrench 6FRONT DRIVE SHAFT(2AZ−FSE)

− PREPARATIONDRIVE SHAFT / PROPELLER SHAFT
02−29
AVENSIS Supplement (RM1045E)
Equipment
Torque wrench
Dial gauge with magnetic base
Lubricant
ItemCapacity
Front drive shaft
Outboard joint grease
Inboard joint grease
152 to162 g (5.4 to 5.7 oz.)
170 to190 g (6.0 to 6.7 oz.)

05−82
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM1045E)
DTC P0130 OXYGEN SENSOR CIRCUIT (BANK1
SENSOR1)
DTC P0150 OXYGEN SENSOR CIRCUIT MALFUNCTION
(BANK 2 SENSOR1)
DTC P2195 OXYGEN SENSOR SIGNAL STUCK LEAN
(BANK1SENSOR1)
DTC P2196 OXYGEN SENSOR SIGNAL STUCK RICH
(BANK1SENSOR1)
DTC P2197 OXYGEN SENSOR SIGNAL STUCK LEAN
(BANK 2 SENSOR1)
DTC P2198 OXYGEN SENSOR SIGNAL STUCK RICH
(BANK 2 SENSOR1)
05CK9−02