TOYOTA AVENSIS 2005 Service Repair Manual

A76719
A76718
A76717
A76717
A
B
A
B 14–24
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
114. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
SST 09301–00210
115. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
SST 09301–00210
116. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)

(See Pub. No. RM1018E on page 41–15)
117. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
118. INSTALL STARTER ASSY (See Pub. No. RM1018E on page 19–3)
119. INSTALL FRONT SUSPENSION CROSSMEMBER
W/CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspen-
sion crossmember and engine mounting member.
(b) Install the bolt which is used to secure the rear engine
mounting bracket onto the mounting insulator.
Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf)
(c) Install the bolt which is used to secure the front engine
mounting bracket onto the mounting insulator.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
120. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670–00010
(a) Set the engine assembly with transaxle on the engine lift-
er.
(b) Temporarily install the suspension crossmember with the
2 bolts and 2 nuts.
(c) Install the engine mounting insulator LH.
Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf)
(d) Install the engine mounting insulator RH.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) for bolt A
133 N⋅m (1,356 kgf⋅cm, 98 ft⋅lbf) for nut B

A76716
AA
BBBBB
B
A76714
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–25
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(f) Install the front suspension member brace LH and RH
with the 8 bolts.
Torque:
133 N⋅m (1,356 kgf⋅cm, 98 ft⋅lbf) for bolt A
80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) for bolt B
121. INSTALL FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30–6)
122. INSTALL FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
123. INSTALL FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30–6)
124. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
125. INSTALL TIE ROD END SUB–ASSY LH (See Pub. No. RM1018E on page 30–6)
126. INSTALL TIE ROD END SUB–ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
127. INSTALL FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30–6)
128. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
129. INSTALL EXHAUST PIPE ASSY FRONT (See Pub. No. RM1018E on page 15–2)
130. INSTALL FLOOR PANEL BRACE FRONT
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
131. INSTALL STEERING INTERMEDIATE SHAFT (See Pub. No. RM1018E on page 50–9)
132. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19–7)
133. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
1ZZ–FE (See Pub. No. RM1018E on page 55–74)
3ZZ–FE (See Pub. No. RM1018E on page 55–70)
134. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)

(See Pub. No. RM1018E on page 41–15)
135. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
136. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts.
Torque: 13 N⋅m (131 kgf⋅cm, 9 ft⋅lbf)

A93669
14–26–
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
137. INSTALL BATTERY
Torque:
5.0 N ⋅m (51 kgf ⋅cm, 44 in. ⋅lbf) for bolt
3.5 N ⋅m (36 kgf ⋅cm, 31 in. ⋅lbf) for nut
138. INSTALL RADIATOR SUPPORT NO.1
(a) Install the 2 radiator supports with the 2 bolts.
Torque: 19 N ⋅m (194 kgf ⋅cm, 14 ft ⋅lbf)
139. INSTALL AIR CLEANER CASE SUB–ASSY
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N ⋅m (51 kgf ⋅cm, 44 in. ⋅lbf)
140. INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10–6)
141. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N ⋅m (71 kgf ⋅cm, 62 in. ⋅lbf)
142. INSTALL FRONT WHEELS
Torque: 103 N ⋅m (1,050 kgf ⋅cm, 76 ft ⋅lbf)
143. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
144. ADD ENGINE OIL
145. ADD ENGINE COOLANT (See page 16–5)
146. CHECK FOR ENGINE OIL LEAKS
147. CHECK FOR ENGINE COOLANT LEAKS (See page 16–1)
148. CHECK FOR FUEL LEAKS
149. CHECK FOR EXHAUST GAS LEAKS
150. CHECK IDLE SPEED AND IGNITION TIMING (See Pub. No. RM1018E on page 14–1)
SST 09843–18040
151. INSPECT CO/HC (See Pub. No. RM1018E on page 14–1)
152. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Pub. No. RM1018E on page \
26–6)
153. CHECK ABS SPEED SENSOR SIGNAL

100P4–01
B66045Claw
A95570
10–12– ENGINE CONTROL SYSTEMACCELERATOR PEDAL ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
ACCELERATOR PEDAL ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE INSTRUMENT PANEL UNDER COVER
SUB–ASSY NO.1
(a) Remove the 2 screws.
(b) Disengage the claw and remove instrument panel under
cover sub–assembly No. 1.
3. REMOVE ACCELERATOR PEDAL ASSY
(a) Disconnect the accelerator pedal sensor connector.
(b) Remove the 2 bolts and accelerator pedal assembly.
4. INSTALL ACCELERATOR PEDAL ASSY
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
5. INSTALL INSTRUMENT PANEL UNDER COVER SUB–ASSY NO.1
6. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)

100P2–01
A95568
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Retainer
Clip
Cylinder Head Cover No. 2
Ventilation Hose No. 1Fuel Vapor Feed Hose No. 1
VSV
Connector
Mass Air Flow
Meter Connector
Fuel Vapor Feed
Hose No. 3
N·m (kgf·cm, ft·lbf)
: Specified torque
x2
7.0 (71, 62 in.⋅lbf)
1.5 (15, 13 in.⋅lbf)
Clip
x4 10–4
– ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
THROTTLE BODY ASSY (1ZZ–FE/3ZZ–FE)(From February,
2004)
COMPONENTS

A95569
Throttle Body Assy
Throttle Control
Motor Connector
Water By–pass Hose No. 2Water By–pass Hosex2x2
 Throttle Body
Gasket
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non–reusable part
9.0 (90, 80 in.⋅lbf)
1ZZ–FE:
 Throttle Body Gasket 3ZZ–FE:
– ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)10–5
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)

–
DIAGNOSTICS CRUISE CONTROL SYSTEM (2AZ–FSE)(From
February, 2004)05–327
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
CRUISE MAIN INDICATOR LIGHT CIRCUIT
CIRCUIT DESCRIPTION
The ECM detects a cruise control switch signal and sends it to the combination m\
eter via BEAN. Then
the CRUISE main indicator light comes on.
The CRUISE main indicator light circuit uses BEAN for communication. If there are any ma\
lfunctions
in this circuit, check for DTCs in the multiplex communication system.
INSPECTION PROCEDURE
1 READ VALUE ON INTELLIGENT TESTER II
(a) Connect the intelligent tester II to the DLC3.
(b) Turn the ignition switch to the ON position and turn the intelligent test\
er II main switch on.
(c) Select the item below in the ”DATA LIST”, and read the display on the intelligent tester II.
CC (ECM):
ItemMeasurement Item /
Display (Range)Normal ConditionDiagnostic Note
CCS Indicator M–CPUCruise indicator signal (Main CPU) / ON or OFFON : ”CRUISE” ON
OFF : ”CRUISE” OFF–
CCS Indicator S–CPUCruise indicator signal (Sub CPU) / ON or OFFON : ”CRUISE” ON
OFF : ”CRUISE” OFF–
OK:
When the cruise control main switch is operated, the display changes as show\
n above.
NG REPLACE ECM(SEE PUB. NO. RM1045E, PAGE 10–29)
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMP TOMS TABLE
( SEE PAGE 05–316 )
05KYG–01

056HK–07
05–316–
DIAGNOSTICS CRUISE CONTROL SYSTEM (2AZ–FSE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
PROBLEM SYMPTOMS TABLE
If a normal system code is displayed during the DTC check but the problem still occurs, check the circuits
for each problem symptom in the order given in the table below and proceed \
to the relevant troubleshooting
page.
HINT:
Inspect the ”Fuse” and ”Relay” before confirming the suspected area\
s as shown in the chart below.
Inspect each malfunction circuit in numerical order for the correspondin\
g symptom.
SymptomSuspected AreaSee Page
Main switch cannot be turned ON.
(Cruise indicator light in combination meter does not come on.)
1. Cruise control switch circuit
2. CRUISE main indicator light circuit
3. ECM
4. Combination meter assy05–322
05–327 *2
*1
Vehicle speed setting cannot be done.
(Although indicator light in combination meter comes on when the
main switch is turned ON, it goes off when vehicle speed is set.)1. Cruise control switch circuit
2. ECM05–322*2
Setting cannot be done.
(Indicator light in combination meter comes on when the main
switch is turned ON and it remains ON while setting.)
1. Cruise control switch circuit
2. Stop lamp switch circuit
3. Park/Neutral position switch circuit
4. Combination meter system
5. ECM05–322
05–318*2
*1
*2
While the vehicle is driven with cruise control, the set control is
cancelled.
(Indicator light and CRUISE remain ON.)
1. Cruise control switch circuit
2. Vehicle speed sensor circuit
3. Stop lamp switch circuit
4. CRUISE main indicator light circuit
5. Park/Neutral position switch circuit
6. ECM
7. Combination meter assy05–322
05–317
05–318
05–327*2
*2
*1
Hunting
(Speed is not constant.)1. Vehicle speed sensor circuit
2. ECM05–317
*2
Setting cannot be cancelled.
(When Coast, Acceleration, Resume, Set speed change and Con-
trol switch are operated.)1. Cruise control switch circuit
2. ECM05–322*2
DTC is not output, or is output when should not be.1. Diagnosis circuit05–328
CRUISE main indicator light does not come on.
1. Cruise control switch circuit
2. CRUISE main indicator light circuit
3. ECM
4. Combination meter assy05–322
05–327*2
*1
*1: See Pub. No. RM1018E
*2: See Pub. No. RM1045E

05KYD–01
I33809
E13 E12 E11E10E9
– DIAGNOSTICSCRUISE CONTROL SYSTEM (2AZ–FSE)(From
February, 2004)05–315
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
TERMINALS OF ECM
Symbols (Terminals No.)Wiring ColorTerminal DescriptionConditionSpecified Condition
TC (E9–20) – E1 (E11–1)W–L – BRDTC input signalIgnition switch ON → Connect ter-
minals TC and CG of DLC310 to 14 V →
Below 2 V
ST1– (E10–12) – E1 (E11–1)G–W – BRCruise cancel input
signalIgnition switch ON, depress brake
pedal → release brake pedalBelow 1 V →
10 to 14 V
STP (E10–19) – E1 (E11–1)G–W – BRStop lamp switch
input signalIgnition switch ON, depress brake
pedal → release brake pedal10 to 14 V →
Below 1 V
CCS (E10–24) – E1 (E11–1)W – BRCruise control main
switch input signal
Ignition switch ON
Cancel switch held ON
SET/COAST switch held ON
RES/ACC switch held ON
MAIN switch held ON10 to 14 V
6.6 to 10.1 V
4.5 to 7.1 V
2.3 to 4 V
Below 1 V

710NI–01
B80612
Code Shape
<A>φ = 8
(0.31)
L = 18
(0.71)Code Shape Code Shapemm (in.) (L = Length)
<B> <C>
<F> <E> <D>
<G> <H> <I>φ = 6
(0.24)
L = 16
(0.63)φ = 6
(0.24)
L = 20
(0.79)
φ = 6
(0.24)
L = 20
(0.79)φ = 6
(0.24)
L = 20
(0.79)φ = 7
(0.28)
L = 20
(0.79)
φ = 5
(0.20)
L = 14
(0.55)φ = 5
(0.20)
L = 14
(0.55)L = 16
(0.63)
B806132 Clips
– INSTRUMENT PANEL/METERINSTRUMENT PANEL SUB–ASSY LOWER (From
February, 2004)71–5
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
HINT:

COMPONENTS: See Pub. No. RM1018E, page 71–7.

Installation is in the reverse order of removal.
1. TABLE OF BOLT, SCREW AND NUT
HINT:
The bolts, screws and nuts, which are necessary for installation and removal of the instrument panel, are
shown in the illustration below with alphabets.
2. DISCONNECT BATTERY NEGATIVE TERMINAL (See Pub. No. RM1018E, page 60–1)
3. REMOVE INSTRUMENT CLUSTER FINISH PANEL
GARNISH NO.1
(a) Disengage the 2 clips and remove the instrument cluster
finish panel garnish No.1.