brake TOYOTA AVENSIS 2005 Service User Guide

± SERVICE SPECIFICATIONSFUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe sub±assy x Injection pump assy
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf

031FW±01
03±44
± SERVICE SPECIFICATIONSPARKING BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wheel nut1031,05076
Parking brake lock nut5.05144 in.
lbf
Parking brake lever sub±assy x Body131279
Front floor heat insulator No.2 x Body5.55649 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
Exhaust pipe installation bolt4344032
Front floor panel brace x Body3030221
Fuel tank protector No.1 x Body5.55649 in.
lbf
Parking brake cable assy No.3 x Fram5.05144 in.
lbf

031FV±01
± SERVICE SPECIFICATIONSPARKING BRAKE
03±43
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE
SERVICE DATA
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):6 ± 9 clicks
Rear brake disc inside diameter Standard
Maximum173 mm (6.81 in.)
174 mm (6.85 in.)
Parking brake shoe lining thickness Standard
Maximum3.5 mm (0.138 in.)
1.0 mm (0.039 in.)

030MV±02
03±42
± SERVICE SPECIFICATIONSBRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wheel nut1031,05076
Brake line union nut 10 mm
14 mm15
29155
29611
21
Brake booster clevis lock nut1919414
Brake master cylinder sub±assy x Brake booster assy2020415
Charcoal canister bracket x Body5.45548 in.
lbf
Brake booster assy x Body131309
Brake pedal support x Instrument panel reinforcement2424117
Brake pedale support x Brake pedal3737527
Brake pedale support x Body131309
Brake tube clamp x body5.45548 in.
lbf
Vacuum pump x Engine2121415
Vacuum pump union nut1414010
Vacuum pump check valve sub±assy x End cover7421454
Vacuum pump end cover x vacuum pump housing7.88069 in.
lbf
Front disc brake bleeder plug101027
Front brake cylinder mounting x Steering knuckle1021,04075
Front disc brake cylinder x Front disc brake cylinder mounting3030622
Front disc brake caliper x Flexible hose2929621
Rear disc brake bleeder plug101027
Rear disc brake cylinder mounting x Steering knuckle4747534
Rear disc brake cylinder x Rear disc brake cylinder mounting3030622
Rear disc brake caliper x Flexible hose2929621
Brake actuator x Brake actuator bracket
w/o VSC:
w/ VSC:7.0
4.771
4862 in.
lbf
42 in.
lbf
Front speed sensor wire harness clamp x shock absorber2929621
Brake actuator bracket x Body1919514
Front speed sensor x Steering knuckle8.08271 in.
lbf
Yawrate sensor bracket set bolt2121415
Yawrate sensor x Yawrate sensor bracket66153 in.
lbf
Yawrate sensor bracket x Body2121415

030MU±02
± SERVICE SPECIFICATIONSBRAKE
03±41
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) RHD:
LHD:
M/T
A/T142.5 ± 152.5 mm (5.610 ± 6.004 in.)
148.1 ± 158.1 mm (5.831 ± 6.224 in.)
149.9 ± 159.9 mm (5.902 ± 6.295 in.)
Brake Pedal free play1 ± 6 mm (0.04 ± 0.24 in.)
Stop light switch clearance0.5 ± 2.6 mm (0.020 ± 0.102 in.)
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf)More than 60 mm (2.36 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front disc brake pad thickness Standard
Minimum12.5 mm (0.492 in.)
2.0 mm (0.079 in.)
Front brake disc thickness Standard
Minimum26.0 mm (1.024 in.)
24.0 mm (0.945 in.)
Front disc runout Maximum0.05 mm (0.0020 in.)
Rear disc brake pad thickness Standard
Minimum10.0 mm (0.394 in.)
2.0 mm (0.079 in.)
Rear disc thickness Standard
Minimum10.0 mm (0.394 in.)
8.0 mm (0.315 in.)
Rear disc runout Maximum0.05 mm (0.0020 in.)

030KC±06
03±40
± SERVICE SPECIFICATIONSDRIVE SHAFT / PROPELLER SHAFT / AXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Front wheel set nut1031,05076
Rear wheel set nut1031,05076
Manual transaxle oil drain plug C50/C250:
E354/E357:39
49400
50029
36
Lower ball joint assy front x Suspension arm sub±assy lower No.18990866
Tie rod end sub±assy x Steering knuckle4950036
Flexible hose and speed sensor front x Shock absorber assy front1919414
Speed sensor front x Steering knuckle8.08271 in.
lbf
Front stabilizer link assy x Shock absorber assy front7475555
Front axle hub nut2162,200159
Disc brake dust cover front x Steering knuckle8.38573 in.
lbf
Lower ball joint assy front x Steering knuckle1031,05076
Front axle assy x Shock absorber assy front2202,243162
Front disc brake caliper assy x Steering knuckle1021,04075
Automatic transaxle fluid drain plug4950036
Drive shaft bearing case x Bearing bracket6465047
Rear axle hub & bearing assy x Rear axle carrier sub±assy5657141
Rear axle carrier sub±assy x Back plate assy1401,428103
Rear axle carrier sub±assy x Skid control sensor wire5.05144 in.
lbf
Rear disk brake caliper assy x Rear axle carrier sub±assy4747534
Rear axle carrier sub±assy x Upper control arm assy7475555
Rear axle carrier sub±assy x Lower control arm assy ball joint side:
member side:60
105612
1,07144
77
Rear axle carrier sub±assy x Rear suspension arm assy ball joint side:
member side:105
741,071
75577
55

031HG±01
± SERVICE SPECIFICATIONSREAR SUSPENSION
03±37
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Hub nut1031,05076
Piston rod set nut5657141
Shock absorber x Body8081659
Shock absorber x Rear suspension arm1601,63211 8
Parking brake cable set bolt5.05144 in.
lbf
Skid control sensor wire harness bracket set bolt5.05144 in.
lbf
Rear suspension arm bracket x body6566348
Rear suspension arm x Rear suspension member7475555
Rear suspension arm bracket x Rear suspension arm11 01,12281
Rear axle carrier (front side) x Rear suspension arm1051,07177
Rear axle carrier (rear side) x Rear suspension arm7475555
Upper control arm x Rear axle carrier7475555
Upper control arm x Suspension member7475555
Lower control arm x Rear axle carrier6061244
Lower control arm x Suspension member1051,07177
Stabilizer bar x Stabilizer link4444932
Stabilizer link x Suspension arm4444932
Stabilizer bar bracket x Suspension member3535726

05C67±01
A66714
E13E12E10E9
05±20
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
TERMINALS OF ECM
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
BATT (E9 ± 3) ± E1 (E12 ± 7)B±Y ± BRAlways8 to 14
FC (E9 ± 10) ± E1 (E12 ± 7)G±Y ±BRIG switch ON8 to 14
FC (E9 ± 10) ± E1 (E12 ± 7)G±Y ±BRIdlingBelow 1.5
W (E9 ± 11) ± E1 (E12 ± 7)W ±BRIdling8 to 14
W (E9 ± 11) ± E1 (E12 ± 7)W ±BRIG switch ONBelow 3.5
+B (E9 ± 1) ± E1 (E12 ± 7)B±R ±BRIG switch ON8 to 14
STP (E10 ± 19) ± E1 (E12 ± 7)G±W ±BRIG switch ON, brake pedal depressed8 to 14
STP (E10 ± 19) ± E1 (E12 ± 7)G±W ±BRIG switch ON, brake pedal releasedBelow 1.5
F/PS (E9 ± 14) ± E1 (E12 ± 7)LG±B ±BRIG switch ONPulse generation
STA (E12 ± 9) ± E1 (E12 ± 7)B±Y ±BRCranking5.5 or more
HT1B (E10 ± 4) ± E03 (E12 ± 5)P ±W±BIdlingBelow 3.0
HT1B (E10 ± 4) ± E03 (E12 ± 5)P ±W±BIG switch ON9 to 14
EMPS (E12 ± 29) ± E1 (E12 ± 7)GR ±BRIG switch ON8 to 14
SPD (E10 ± 17) ± E1 (E12 ± 7)V±W ±BRIG switch ON, rotate driving wheel slowlyPulse generation
(See page 05±98)
OX1B (E12 ± 21) ± E2 (E13 ± 28)B ±BRMaintain engine speed at 2,500 rpm for 2 min. after warning upPulse generation
(See page 05±91)
TACH (E9 ± 5) ± E1 (E12 ± 7)GR±R ±BRIdlingPulse generation
VC (E13 ± 18) ± E2 (E13 ± 28)R±W ±BRIG switch ON4.5 to 5.5
HT1A (E12 ± 4) ± E03 (E12 ± 5)Y ±W±BIdlingBelow 3.0
HT1A (E12 ± 4) ± E03 (E12 ± 5)Y ±W±BIG switch ON9 to 14
EVP1 (E13 ± 12) ± E01 (E13 ± 7)W±G ±W±BIG switch ON8 to 14
VG (E12 ± 24) ± EVG (E12 ± 32)G ±L±YIdling, A/C switch OFF1.1 to 1.5
OX1A (E12 ± 23) ± E2 (E13 ± 28)B ±BRMaintain engine speed at 2,500 rpm for 2 min. after warning upPulse generation
(See page 05±91)
THW (E13 ± 19) ± E2 (E13 ± 28)B±W ± BRIdling, Engine coolant temp. at 80
C (176
F)0.2 to 1.0
G2 (E13 ± 26)
± NE± (E13 ± 34)W ± RIdlingPulse generation
(See page 05±84)
NE+ (E13 ± 27) ± NE± (E13 ± 34)G ± RIdlingPulse generation
(See page 05±84)
THA (E13 ± 20) ± E2 (E13 ± 28)G±R ± BRIdling, intake air temp. at 20
C (68
F)0.5 to 3.4

± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±115
AVENSIS REPAIR MANUAL (RM1018E)
DTC P1520 STOP LIGHT SWITCH CIRCUIT
MALFUNCTION
CIRCUIT DESCRIPTION
This signal is used to detect that the brakes have been applied. The STP signal voltage is the same as the
one supplied to the stop lights.
The STP signal is used mainly to control the fuel cut±off engine speed (The fuel cut±off engine speed is re-
duced slightly when the vehicle is braking.).
DTC No.DTC Detecting ConditionTrouble Area
P1520
Condition (a), (b) and (c) continue for 0.5 sec. or more:
(a) Ignition switch ON
(b) Brake pedal released
(c) STP signal is OFF when the STP signal is OFF
Open or short in stop light switch signal circuit

Stop light switch

ECM
05B48±02

± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±117
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using    
 Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running
or stopped, the engine was warmed up or not, the air±fuel ratio was lean or rich, etc. at the time of the mal-
function.
1 CHECK OPERATION OF STOP LIGHT
(a) Check if the stop lights go on and off normally when the brake pedal is depressed and released.
NG REPAIR OR REPLACE STOP LAMP SWITCH
CIRCUIT
OK
2 READ VALUE OF HAND±HELD TESTER
(a) Connect the hand±held tester to the DLC3.
(b) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / STOP LIGHT SWº and read its value
displayed the hand±held tester.
(c) Turn the ignition switch ON and push the hand±held tester main switch ON.
(d) Read the STP signal on the hand±held tester.
Result:
Brake PedalSTP Signal
DepressedON
ReleasedOFF
OK CHECK FOR INTERMITTENT PROBLEMS
NG