TOYOTA AVENSIS 2005 Service Repair Manual

600K8–02
H42769
60–6
– SUPPLEMENTAL RESTRAINT SYSTEMAIR BAG SENSOR REAR LH (From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
HINT:
Use the same procedures for the RH side and LH side.
1. PRECAUTION (SEE PUB. NO. RM1018E, PAGE 60–1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
3. REMOVE REAR DOOR SCUFF PLATE LH (SEE PUB. NO. RM1018E, PAGE 73–36)
4. REMOVE REAR SEAT CUSHION ASSEMBLY (FIXED TYPE REAR SEAT) (SEE PUB. NO.
RM1018E, PAGE 72–33)
5. REMOVE REAR SIDE SEAT BACK ASSY LH (SEPARATED TYPE REAR SEAT) (SEE PUB. NO.
RM1018E, PAGE 72–27)
6. REMOVE AIR BAG SENSOR REAR LH
(a) Disconnect the connector from the airbag sensor rear LH.
(b) Remove the 2 bolts and the airbag sensor rear LH.
7. INSTALL AIR BAG SENSOR REAR LH
(a) Check that the ignition switch is off.
(b) Check that the battery negative (–) terminal is disconnected.
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
(c) Install the airbag sensor rear LH with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 ft⋅lbf)
NOTICE:

If the airbag sensor rear LH has been dropped, or there are any cracks, dents or other defects
in the case, bracket or connector, replace it with a new one.

When installing the airbag sensor rear LH, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the airbag sensor rear LH.
(e) Connect the connector to the airbag sensor rear LH.
8. CONNECT BATTERY NEGATIVE TERMINAL
9. INSPECT SRS WARNING LIGHT (SEE PUB. NO. RM1018E, PAGE 05–1184)

600K7–02
H42768
Rear Door Scuff Plate LH
Rear Side Seat Back Assy LH
Airbag Sensor Rear LH
9.0 (92, 80 in.⋅lbf)
Rear Seat Cushion Assembly Fixed Type Rear Seat:
Separated Type Rear Seat:
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
– SUPPLEMENTAL RESTRAINT SYSTEMAIR BAG SENSOR REAR LH (From February, 2004)
60–5
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
AIR BAG SENSOR REAR LH (From February, 2004)
COMPONENTS

600A7–04
H42767
60–4– SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIR BAG SENSOR ASSY LH (From February,
2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
HINT:
Use the same procedures for the RH side and LH side.
1. PRECAUTION (SEE PUB. NO. RM1018E, PAGE 60–1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
3. REMOVE FRONT DOOR SCUFF PLATE LH (SEE PUB. NO. RM1018E, PAGE 76–36)
4. REMOVE REAR DOOR SCUFF PLATE LH (SEE PUB. NO. RM1018E, PAGE 76–36)
5. REMOVE FRONT DOOR WEATHERSTRIP LH (SEE PUB. NO. RM1018E, PAGE 76–36)
6. REMOVE REAR DOOR WEATHERSTRIP LH (SEE PUB. NO. RM1018E, PAGE 76–36)
7. REMOVE CENTER PILLAR GARNISH LOWER LH (SEE PUB. NO. RM1018E, PAGE 76–36)
8. REMOVE FRONT SEAT OUTER BELT ASSY LH (SEE PUB. NO. RM1018E, PAGE 61–7)
9. REMOVE SIDE AIR BAG SENSOR ASSY LH
(a) Disconnect the connector from the side airbag sensor
assy LH.
(b) Remove the nut and the side airbag sensor assy LH.
10. INSTALL SIDE AIR BAG SENSOR ASSY LH
(a) Check that the ignition switch is off.
(b) Check that the battery negative (–) terminal is disconnected.
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
(c) Install the side airbag sensor assy LH with the nut.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
NOTICE:

If the side airbag sensor assy LH has been dropped, or there are any cracks, dents or other de-
fects in the case, bracket or connector, replace it with a new one.

When installing the side airbag sensor assy LH, be careful that the SRS wiring does not interfere
with other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the side airbag sensor assy LH.
(e) Connect the connector to the side airbag sensor assy LH.
11. INSTALL FRONT SEAT OUTER BELT ASSY LH (SEE PUB. NO. RM1018E, PAGE 61–7)
12. CONNECT BATTERY NEGATIVE TERMINAL
13. INSPECT SRS WARNING LIGHT (SEE PUB. NO. RM1018E, PAGE 05–1184)

600UO–01
H44212N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Rear Door Opening
Trim Weatherstrip LH
Rear Door Scuff
Plate LH
Center Pillar
Garnish Lower LH
Front Door Scuff
Plate LHFront Door Opening Trim
Weatherstrip LHFront Seat
Outer Belt Assy LH
9.0 (92, 80 in.⋅lbf)
Side Airbag Sensor Assy LH
42 (428, 31)
7.5 (77, 66 in.⋅lbf)
– SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIR BAG SENSOR ASSY LH (From February,
2004)60–3
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
SIDE AIR BAG SENSOR ASSY LH (From February, 2004)
COMPONENTS

600K6–02
H42699
60–2
– SUPPLEMENTAL RESTRAINT SYSTEMAIR BAG SENSOR FRONT LH (From February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
REPLACEMENT
HINT:
Use the same procedures for the RH side and LH side.
1. PRECAUTION (SEE PUB. NO. RM1018E, PAGE 60–1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
3. REMOVE AIR BAG SENSOR FRONT LH
(a) Disconnect the connector from the airbag sensor front
LH.
(b) Remove the 2 bolts and the airbag sensor front LH.
4. INSTALL AIR BAG SENSOR FRONT LH
(a) Check that the ignition switch is off.
(b) Check that the battery negative (–) terminal is disconnected.
CAUTION:
After removing the terminal, wait for at least 90 seconds before starting the operation.
(c) Install the airbag sensor front LH with the 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
NOTICE:

If the airbag sensor front LH has been dropped, or there are any cracks, dents or other defects
in the case, bracket or connector, replace it with a new one.

When installing the airbag sensor front LH, be careful that the SRS wiring does not interfere with
other parts and that it is not pinched between other parts.
(d) Check that there is no looseness in the installation parts of the airbag sensor front LH.
(e) Connect the connector to the airbag sensor front LH.
5. CONNECT BATTERY NEGATIVE TERMINAL
6. INSPECT SRS WARNING LIGHT (SEE PUB. NO. RM1018E, PAGE 05–1184)

190OJ–03
A95771
N·m (kgf·cm, ft·lbf)
: Specified torque PulleyDrive End Frame
Generator Rotor Assy
Stator Sub–assy
Generator W/ Rectifier Spacer Ring
Generator Rear End Cover
Regulator Sub–assy
Generator W/ Brush Spring Washer

Non–reusable part
Fitting Ring
Terminal
Cover
68 (688, 50)
3.5 (36, 31 in.⋅lbf)19.5 (199, 14)
2.2 (22, 19 in.⋅lbf)
2.4 (24, 21 in.⋅lbf)
1.2 (12, 11 in.⋅lbf)
12 (122, 9)
x4
x2
– STARTING & CHARGINGGENERATOR ASSY (BOSCH MADE)(1ZZ–FE/3ZZ–FE)
19–21
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
GENERATOR ASSY (BOSCH MADE)(1ZZ–FE/3ZZ–FE)
COMPONENTS

141TK–01
A95716
A95719Dial Gauge
A95720Dial Gauge
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–51
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
OVERHAUL
1. REMOVE CYLINDER BLOCK WATER DRAIN COCK
SUB–ASSY
(a) Remove the cylinder block water drain cock from the cyl-
inder block.
2. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Turn the crankshaft and set the No. 1 cylinder to the TDC/
compression.
(b) Using a dial indicator, measure the thrust clearance of the
No. 2 and No. 3 cylinders while moving the connecting rod
back and forth.
Standard thrust clearance:
0.160 to 0.342 mm (0.0063 to 0.0135 in.)
Maximum thrust clearance:
0.342 mm (0.0135 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod.
If necessary, replace the crankshaft.
(c) Turn the crankshaft and set the No. 2 cylinder to the TDC/
compression.

A95722
Matchmark
A95724
SST
14–52
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(d) Using a dial indicator, measure the thrust clearance of the
No. 1 and No. 4 cylinders while moving the connecting rod
back and forth.
Standard thrust clearance:
0.160 to 0.342 mm (0.0063 to 0.0135 in.)
Maximum thrust clearance:
0.342 mm (0.0135 in.)
If the thrust clearance is greater than maximum, re-
place the connecting rod.
If necessary, replace the crankshaft.
3. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Turn the crankshaft and set the No. 1 cylinder to the TDC/
compression.
(b) Measure the oil clearance of the No. 2 and No. 3 cylin-
ders.
NOTICE:
Do not turn the crankshaft during the measurement.
(1) Using marking paint, write the matched cylinder
number on each connecting rod and cap.
HINT:
The matchmarks on the connecting rods and caps are for en-
suring correct reassembling.
(2) Using SST, remove the 4 bolts and 2 connecting rod
caps as shown.
SST 09205–16010
(3) Clean the crank pin and bearing.
(4) Check the crank pin and bearing for pitting and
scratches.

A95725
Plastigage
A95726
Front Mark
A95724
SST
A65715
Paint Mark90 Engine
Front
A95724
SST
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
14–53
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(5) Lay a strip of Plastigage across the crank pin.
(6) Check that the front marks of the 2connecting rod
caps are facing in the correct direction.
(7) Apply a light coat of engine oil to the threads and un-
der the heads of the connecting rod cap bolts.
(8) Using SST, tighten the 2 bolts in several passes to
the specified torque.
SST 09205–16010
Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf)
(9) Mark the front of the connecting cap bolts with paint.
(10) Retighten the cap bolts by an additional 90 as
shown in the illustration.
(11) Check that the crankshaft turns smoothly.
(12) Remove the 4 bolts and 2 connecting rod caps.

A95728
A95729
Connecting Bearing Cap: Connecting Bearing:
TAIHO Mark Lot. Number Mark
TAIHO Made
FEDERAL MOGUL
/GLYCO Made
MarkMark
14–54
– ENGINE MECHANICALCYLINDER BLOCK ASSY (1ZZ–FE/3ZZ–FE)
1ZZ–FE,3ZZ–FE ENGINE REPAIR MANUAL
(RM1099E)
(13) Measure the Plastigage at its widest point.
Standard oil clearance:
0.028 to 0.060 mm (0.0011 to 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
NOTICE:
Remove the Plastigage completely after the measurement.
If the oil clearance is greater than maximum, re-
place the connecting rod bearing.
If necessary, grind or replace the crankshaft.
HINT:
The TAIHO mark is either on the claw side or the opposite
side.
If replacing a bearing, select a new one having the same
number as marked on the connecting rod. There are 3
sizes of standard bearings, marked ”1”, ”2” and ”3” ac-
cordingly.
ItemMarkSpecification
Connecting rod bearing cap
bore diameter1
2
347.000 to 47.008 mm (1.8504 to 1.8507 in.)
47.009 to 47.016 mm (1.8507 to 1.8510 in.)
47.017 to 47.024 mm (1.8511 to 1.8513 in.)
Connecting rod bearing
thickness1
2
31.486 to 1.490 mm (0.0585 to 0.0587 in.)
1.491 to 1.494 mm (0.0587 to 0.0588 in.)
1.495 to 1.498 mm (0.0589 to 0.0590 in.)
Crankshaft pin outer diame-
ter–43.992 to 44.000 mm (1.7320 to 1.7323 in.)
(c) Turn the crankshaft and set the No. 2 cylinder to the TDC/
compression.