steering wheel TOYOTA AVENSIS 2005 Service User Guide

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

0313B±05
03±34
± SERVICE SPECIFICATIONSFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1
± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference0
06'
12' (0.1

0.2
), 1
2 mm (0.04
0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

17'  2

 

32
52' 


42'  2

 

33
16' 

Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

47'  2
 
 

31
15' 


09'  2


 

31
38' 


Camber
Normal package
Rough road package
Right±left error
±0
34'  45' (±0.57
 0.75
)
±0
19'  45' (±0.32
 0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error

54'  45' (2.90
 0.75
)

40'  45' (2.67
 0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27'  45' (12.45
 0.75
)
11
56'  45' (11.93
 0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center

031H6±01
03±28
± SERVICE SPECIFICATIONSLUBRICATION
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan3737727
Oil pump x Cylinder block9.09280 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.
lbf
Oil pan sub±assy x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket RH x Body LHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Engine x wire7.07162 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Return tube x Body8.08271 in.
lbf
Ignition coil assy x Cylinder head cover9.09280 in.
lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.
lbf
Front wheel RH1031,05076
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.
lbf
Oil pan sub±assy x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket RH x Body LHD steering position type9.09280 in.
lbf
Engine x wire7.07162 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD steering position type9.09280 in.
lbf
Return tube x Body8.08271 in.
lbf
Ignition coil assy x Cylinder head cover9.09280 in.
lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.
lbf
Front wheel RH1031,05076
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Oil drain plug x Oil pan sub±assy No. 23435025
Oil pump x Cylinder block3132023

031HM±01
± SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
03±63
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Horn button assy x Steering wheel assy8.89078 in.
lbf
Steering wheel assy x Steering column assy5051037
Instrument panel passenger airbag assy x Instrument panel reinforcement2020014
Curtain shield airbag assy x Body3.53631 in.
lbfCurtain shield airbag assy x Body3.5
14
36
143
31 in.lbf
10
Instrument panel airbag assy x Instrument panel reinforcement1818413
Airbag sensor assy center x Body17.517813
Airbag front sensor set bolt7.57666 in.
lbf
Side airbag sensor assy LH x Body17.517813
Airbag sensor rear LH x Body17.517813
Seat position airbag sensor x Front seat8.08271 in.
lbf

030G7±04
03±60
± SERVICE SPECIFICATIONSPOWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN
mkgf
cmft
lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356
81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.
lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)

030G6±04
± SERVICE SPECIFICATIONSPOWER STEERING
03±59
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING
SERVICE DATA
POWER STEERING FLUID
Fluid level rise Maximum5 mm (0.20 in.)
Fluid pressure at idle speed with valve closed AZ Series:
1CD±FTV:8,300 to 9,000 kPa (85 to 92 kgf/cm2, 1,204 to 1,305 psi)
8,800 to 9,500 kPa (90 to 97 kgf/cm2, 1,276 to 1,378 psi)
STEERING WHEEL
Steering effort at idle speed (Reference)5.5 N´m (56 kgf´cm, 49 in.´lbf)
VANE PUMP ASSY
Vane pump rotating torque0.27 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
Vane pump shaft and vane pump housing oil clearance Maximum0.07 mm (0.0028 in.)
Vane plate thickness Minimum1.405 to 1.411 mm (0.05531 to 0.05555 in.)
Clearance between the rotor groove and plate Maximum0.03 mm (0.0012 in.)
Spring free length Minimum36.9 mm (1.453 in.)
STEERING GEAR ASSY
Total preload (Tie rod rotating torque) (Turning)0.29 to 1.96 N´m (3 to 20 kgf´cm, 2.57 to 17.35 in.´lbf)
Total preload (Control valve rotating torque) (Turning)0.6 to 1.1 N´m (6 to 11 kgf´cm, 5.3 to 9.7 in.´lbf)
RACK & PINION POWER STEERING GEAR ASSY
Total preload (Tie rod rotating torque) (Turning)0.49 to 3.43 N´m (5 to 35 kgf´cm, 4.34 to 30.38 in.´lbf)

031FZ±01
03±58
± SERVICE SPECIFICATIONSSTEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Steering intermediate shaft assy No. 2 x Oil pressure power steering
column assy (LHD steering positoin type)2828621
Steering sliding yoke sub±assy x Oil pressure power steering column assy
(RHD steering positoin type)2828621
Steering intermediate shaft assy No. 2 x Electric power steering column
assy (LHD steering positoin type)3536026
Steering sliding yoke sub±assy x Electric power steering column assy
(RHD steering positoin type)3536026
Steering sliding yoke sub±assy x Steering intermediate shaft assy No. 23536026
Steering column assy set bolt2121415
Steering sliding yoke sub±assy x Steering gear assy
(LHD steering positoin type)3536026
Steering intermediate shaft assy No. 2 x Steering gear assy
(RHD steering positoin type)3536026
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
Steering column cover LWR x Steering column assy5.05144 in.´lbf
Instrument panel airbag assy1818413
Power steering ECU assy (Bolt A)88271 in.´lbf
Power steering ECU assy (Bolt B)15.515811

031FX±01
± SERVICE SPECIFICATIONSSTEERING COLUMN
03±57
AVENSIS REPAIR MANUAL (RM1018E)
STEERING COLUMN
SERVICE DATA
STEERING SYSTEM
Steering wheel freeplay Maximum30 mm (1.18 in.)

030L1±03
± SERVICE SPECIFICATIONSCLUTCH
03±55
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
SERVICE DATA
Pedal height from asphalt sheet
LHD steering position type
1CD±FTV engine type w/ intercooler
Others
154.0 ± 164.0 mm (6.063 ± 6.457 in.)
139.6 ± 149.6 mm (5.496 ± 5.890 in.)
Pedal height from asphalt sheet
RHD steering position type
1CD±FTV engine type w/ intercooler
Others
158.4 ± 168.4 mm (6.236 ± 6.630 in.)
148.4 ± 158.4 mm (5.843 ± 6.236 in.)
Clutch pedal free play5.0 ± 15.0 mm (0.197 ± 0591 in.)
Clutch pedal push rod play at pedal top1.0 ± 5.0 mm (0.039 ± 0.197 in.)
Slotted spring pin protrusion1.5 ± 3.5 mm (0.059 ± 0.138 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch disc rivet head depth Maximum0.3 mm (0.012 in.)
Clutch disc assy runout Minimum0.8 mm (0.031 in.)
Diaphragm spring finger wear Maximum depth:
Maximum width:0.5 mm (0.020 in.)
6.0 mm (0.236 in.)
Flywheel sub±assy runout Maximum0.1 mm (0.004 in.)
Diaphragm tip alignment Maximum0.5 mm (0.020 in.)

± DIAGNOSTICSSFI SYSTEM (1AZ±FSE)
05±305
AVENSIS REPAIR MANUAL (RM1018E)Hand±held Tester DisplayDiagnostic Note Normal Condition *
1Measurement Item/Range
(Display)
ELECT LOAD SIGElectrical load signal/
ON or OFF
Tail light switch ON: ON

Defogger switch ON: ON

STOP LIGHT SWStop light switch/
ON or OFF
Brake pedal depressed: ON

Brake pedal released: OFF

PS OIL PRESS SWPower steering signal/
ON or OFF

While turning the steering wheel:
ON

While not turning the steering
wheel: OFF
The idle±up control is performed
when PS is ON.
PS SIGNALPower steering signal/
ON or OFFWhen the steering wheel is turned:
ONThis signal is usually ON status
until the IG switch is turned OFF.
SCV VSVVSV status for intake air control
valve/ ON or OFFVSV operation: ON

FUEL PUMP / SPDFuel pump/speed status/
ON/H or OFF/M,LIdling: ON

EVAP VSVVSV status for EVAP control/
ON or OFFVSV operating: ONVSV for EVAP is controlled by the
ECM (ground side duty control)
VVT CTRL B1VVT control status (bank 1)/
ON or OFFVVT system operation: ON

IGNITIONIgnition counter/ Min.: 0, Max.: 4000 to 400

CYL #1, #2, #3, #4Misfire ratio of the cylinder 1 to 4/
Min.: 0 %, Max.: 50 %0 %This item is displayed in only idling
MISFIRE RPMEngine RPM for first misfire range/
Min.: 0 rpm, Max.: 6,375 rpmMisfire 0: 0 rpm

FC TAUFuel Cut TAU: Fuel cut during very
light load/ ON or OFFFuel cut operating: ON
The fuel cut is being performed un-
der very light load to prevent the
engine combustion from becoming
incomplete.
CHECK MODECheck mode/ ON or OFFCheck mode ON: ONSee step 3
O2 RL B1 S2
Oxygen sensor rich lean bank 1
sensor 2:
Response time for oxygen sensor
output to switch from rich to lean/
Min.: 0 ms, Max.: 16,702.5 ms
Idling after warming up:
O2 RL B2 S2
Oxygen sensor rich lean bank 2
sensor 2:
Response time for oxygen sensor
output to switch from rich to lean/
Min.: 0 ms, Max.: 16,702.5 ms
Idling after warming u:
0 to 1,000 msec.

MIL ON RUN DIST
Distance since activation of check
engine warning light/
Min.: 0 km, Max.: 65,535 km
When there is no DTC: 0 km

FUEL PRESS
Fuel high pressure inside fuel de-
livery pipe/
Min.: 0 MPa, Max.: 819 MPa
Idling: 8 to 13 MPa

Running without load (3,000
rpm): 9.5 to 10.5 MPa


*1: If no conditions are specifically stated for ºldlingº, it means the shift lever is at the N or P position, the A/C
switch is OFF and all accessory switches are OFF.
*
2: For A/T only