ground TOYOTA AVENSIS 2003 Service Owner's Manual

030ND±02
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
Floor shift transmission control cable assy x Body5.05144 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
FLOOR SHIFT SHIFT LEVER ASSY
Floor shift shift lever assy x Body121229
MANUAL TRANSAXLE ASSY (1ZZ±FE/ 3ZZ±FE)
Filler and drain plugs3940029
Engine hanger set bolt3838728
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
47
23650
480
23047
35
17
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Starter assy x Manual transaxle assy3738027
Starter wire set nut131309
Clutch release cylinder assy x TransaxleBolt A:
Bolt B:
Bolt C:25
14
5.0250
141 2119
10
44 in.
lbf
Manual transaxle assy x Wire harness clmap Bolt A:
Bolt B:26
19260
19519
14
Manual transaxle assy x Ground cable Bolt A:
Bolt B:26
40260
41019
30
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head cover No.2 x Engine7.07162 in.
lbf
Hood set bolt1313310
MANUAL TRANSAXLE ASSY (1AZ±FE/ 1AZ±FSE)
Filler and drain plugs4950036
Engine hanger x Engine3838728
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Manual transaxle assy x Ground cableBolt A:
Bolt C:26
40260
41019
30
Manual transaxle assy x Wire harness clamp8.48574 in.
lbf
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:9.0
1292
12080 in.
lbf
9
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03±54
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Engine cover sub±assy No.1 x Engine9.09280 in.
lbf
Hood set bolt1313210
MANUAL TRANSAXLE ASSY (1CD±FTV)
Filler and drain plugs4950036
Engine hanger x Engine3737727
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:
Bolt D:
Bolt E:64
46
40
20
8.0653
469
408
200 8247
34
30
14
71 in.
lbf
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Accumulator to flexible hose tube x TransaxleBolt A:
Bolt B:
Bolt C:12
5.0
9.0120 51
929
44 in.
lbf
80 in.
lbf
Manual transaxle assy x Ground cable131319
Air tube No.2 x Transaxle2525518
Starter assy x Transaxle3738027
Starter wire set nut131309
Radiator reserve tank assy x Body6.06153 in.
lbf
Air tube No.1 x Engine2525518
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body7.07162 in.
lbf
Engine cover No.1 x Engine8.08271 in.
lbf
Hood set bolt1313310
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A78508
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Throttle Body Assy
Throttle Motor Connector

Throttle Body Gasket
Water By±pass Hose No. 2
Water By±pass Hose No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground Terminal
Wire Harness Protector
8.4 (86, 74 in.
lbf)
10±48
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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A78508
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Throttle Body Assy
Throttle Motor Connector

Throttle Body Gasket
Water By±pass Hose No. 2
Water By±pass Hose No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground Terminal
Wire Harness Protector
8.4 (86, 74 in.
lbf)
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (1AZ±FSE)
10±43
AVENSIS REPAIR MANUAL (RM1018E)
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A78511
(b)
A78512
(d)
A78513
(g)
(h)
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1AZ±FSE)
10±45
AVENSIS REPAIR MANUAL (RM1018E)
(b)Remove the bolt, and then remove the ground terminal.
(c)Remove the 4 bolts, and then remove the throttle body
bracket.
(d)Disconnect the throttle motor connector.
(e)Remove the 4 bolts, and then remove the throttle body.
(f)Remove the gasket from the intake manifold.
(g)Disconnect the water by±pass hose No. 1.
(h)Disconnect the water by±pass hose No. 2.
7.INSTALL THROTTLE BODY ASSY
(a)Connect the water by±pass hose No. 2.
(b)Connect the water by±pass hose No. 1.
(c)Install a new gasket to the intake manifold.
(d)Install the throttle body with the 4 bolts. Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(e)Connect the throttle motor connector.
(f)Install the throttle body bracket with the 4 bolts. Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
(g)Install the ground terminal with the bolt. Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
(h)Install the wire harness protector with the bolt. Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
8.INSTALL AIR CLEANER CAP SUB±ASSY Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
9.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
10.ADD ENGINE COOLANT (See page 16±31)
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
12. INSTALL ENGINE ROOM COVER SIDE
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A78508
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Throttle Body Assy
Throttle Motor Connector

Throttle Body Gasket
Water By±pass Hose No. 2
Water By±pass Hose No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground Terminal
Wire Harness Protector
8.4 (86, 74 in.
lbf)
11±38
±
FUEL FUEL INJECTOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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A78508
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Throttle Body Assy
Throttle Motor Connector

Throttle Body Gasket
Water By±pass Hose No. 2
Water By±pass Hose No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground Terminal
Wire Harness Protector
8.4 (86, 74 in.
lbf)
11±50
±
FUEL FUEL PUMP ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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1209J±02
A77127
Ohmmeter
Resistance
A77128No Continuity Ohmmeter
A77129
Vacuum
A77130
6V
Vacuum
12±18
±
EMISSION CONTROL EGR SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT VACUUM REGULATING VALVE ASSY
(a) Inspect E±VRV for open circuit (1) Using an ohmmeter, measure resistance betweenthe terminals.
Resistance:
10 to 14
at 20
C (68
F)
(b) Inspect E±VRV for ground (1) Using an ohmmeter, check that there is no continu-ity between each terminal and the body.
Specified condition : No continuity
(c) Inspect E±VRV for air tightness (1) Apply vacuum to the vacuum output port. Checkthat the needle of vacuum pump indicates an in-
crease of 66.7 kPa (500 mmHg, 19.7 in.Hg) or
more.
If the air tightness is not as specified, replace the E±VRV.
(d) Inspect E±VRV operation (1) Apply about 4 dry batteries of 1.5V in series.
(2) Check that the need does not move when vacuumis applied to the vacuum outlet port.
If operation is not as specified, replace the E±VRV.
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A77115
Ohmmeter
Resistance
A77116
Ohmmeter
No continuity
A77117
Air
E
F
A77118
Air
E
F
Battery
A61829
+BHT
E1
Bank 1 Sensor 1:
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FE)
12±9
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect VSV for open circuit.
(1) Using an ohmmeter, measure resistance between
the terminals.
Resistance: 26 to 30
at 20
C (68
F)
If the resistance is not as specified, replace the VSV.
(b) Inspect the VSV for ground. (1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
If there is continuity, replace the VSV.
(c) Inspect the VSV operation. (1) Check that air flows with a little difficulty from port Eto port F.
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to port F.
If operation is not as specified, replace the VSV.
5. INSPECT AIR FUEL RATIO SENSOR
(a) Bank 1 Sensor 1: (1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Terminal No.Resistance
1 (HT) ± 2 (+B)1.8 to 3.4
at 20
C (68
F)
1 (HT) ± (+B)5.0 to 7.5
at 500
C (932
F)
1 (HT) ± 4 (E1)No Continuity
If the resistance is not as specified, replace the sensor.
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A77115
Ohmmeter
Resistance
A77116
Ohmmeter
No continuity
A77117
Air
E
F
A77118
Air
E
F
Battery
A64543
+B
Bank 2 Sensor 1: HT
E1
12±14
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect VSV for open circuit. (1) Using an ohmmeter, measure resistance between
the terminals.
Resistance: 26 to 30
at 20
C (68
F)
If the resistance is not as specified, replace the VSV.
(b) Inspect the VSV for ground. (1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
If there is continuity, replace the VSV.
(c) Inspect the VSV operation. (1) Check that air flows with a little difficulty from port Eto port F.
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to port F.
If operation is not as specified, replace the VSV.
5. INSPECT HEATED OXYGEN SENSOR
(a) Bank 2 Sensor 1: (1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Terminal No.Resistance
1 (HT) ± 2 (+B)11 to 16
at 20
C (68
F)
1 (HT) ± 4 (E1)No Continuity
If the resistance is not as specified, replace the sensor.
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