ignition TOYOTA AVENSIS 2005 Service Repair Manual

A76719
A62838SST
A62838SST
A76713
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–15
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(b) Remove the through bolt, then detach the engine mount-
ing insulator RR from the suspension crossmember.
(c) Separate the engine and the transaxle assembly from the
suspension crossmember and engine mounting member.
60. REMOVE STARTER ASSY (See Pub. No. RM1018E on page 19–3)
61. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
(See Pub. No. RM1018E on page 41–15)
62. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
63. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
64. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See Pub. No. RM1018E on page 42–26)
65. REMOVE FLYWHEEL SUB–ASSY (M/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
flywheel.
SST 09960–10010 (09962–01000, 09963–01000)
66. REMOVE DRIVE PLATE & RING GEAR SUB–ASSY
(A/T TRANSAXLE)
(a) Hold the crankshaft with SST, then remove the 8 bolts and
drive plate & ring gear.
SST 09960–10010 (09962–01000, 09963–01000)
67. REMOVE IGNITION COIL ASSY
(a) Disconnect the 4 ignition coil connectors.
(b) Remove the 2 nuts which are used to secure the engine
wire.

A64023
A93668
A64026
A96570
14–16– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(c) Remove the 4 bolts and 4 ignition coils.
68. REMOVE FUEL DELIVERY PIPE SUB–ASSY
(See Pub. No. RM1018E on page 11–11)
69. REMOVE INTAKE MANIFOLD
(a) Disconnect the throttle motor connector.
(b) Disconnect the 2 water hoses from the throttle body.
(c) Disconnect the ventilation hose and ventilation hose No.
2 from the cylinder head cover.
(d) Disconnect the vacuum hose from water by–pass pipe
No. 1.
(e) Remove the 4 bolts, 2 nuts and 2 wire brackets,then re-
move the intake manifold and throttle body assembly.
(f) Remove the gasket from the intake manifold and the
throttle body assembly.
70. REMOVE OIL LEVEL GAGE SUB–ASSY
(a) Remove the oil level gage from the oil level gage guide.
71. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crankshaft position sensor clamp.
(b) Remove the bolt and oil level gage guide.
72. REMOVE WATER BY–PASS PIPE NO.1
(a) Disconnect the knock sensor clamp.
(b) Remove the 2 bolts and 2 nuts, then detach the water by–
pass pipe and gasket.

A96570
A64026
A93668
A64023
A76713
14–22– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
107. INSTALL WATER BY–PASS PIPE NO.1
(a) Install a new gasket and water by–pass pipe with the 2
nuts and 2 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
108. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O–ring and install
it onto the oil level gage guide.
(b) Install the oil level gage guide with the bolt.
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)
109. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.
(b) Install the intake manifold and 2 clamp brackets with the
2 nuts and 4 bolts.
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
110. INSTALL FUEL DELIVERY PIPE SUB–ASSY

(See Pub. No. RM1018E on page 11–11)
111. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅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

–
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

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

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)

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)

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)