TOYOTA AVENSIS 2005 Service Repair Manual

F44616
89 (908, 66)
102 (1,040, 75)
220 (2,240, 162)
8 (82, 71 in.
lbf)
49 (500, 36)
103 (1,050, 76)
216 (2,200, 159)
Front Shock Absorber with Coil Spring
Front Drive Shaft Assy LHSpeed Sensor Front LH
Cotter Pin
Front Disc
Tie Rod End
Sub±assy LH
Cotter Pin
Front Disc Brake
Caliper Assy LH
Front Suspension Arm
Sub±assy Lower No.1 LH
Lower Ball Joint Assy Front LH
Front Axle Assy LHFront Axle Hub LH Nut
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part



26±4
± FRONT SUSPENSIONFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)

F45154
Rack & Pinion
Power Steering Gear Assy
Tie Rod End
Sub±assy LH
Front Stabilizer Link
Assy LH
Stabilizer Bar Front Front Stabilizer Link
Assy RH
Front Suspension Arm
Sub±assy Lower No.1 RH
Front Suspension
Member Brace
Rear RHFront Stabilizer
Bar Bush No.1
Front Suspension
Crossmember Sub±assy
Front Suspension
Arm Sub±assy
Lower No.1 LH
Body Mounting
Stopper Rear
Front Suspension
Member Body
Mounting Stopper FR
Front Suspension
Member Brace Rear LH
Cotter Pin

89 (908, 66)
133 (1,360, 98)
49 (500, 36)
74 (755, 55)
80 (816, 59)
133 (1,360, 98)
74 (755, 55)
49 (500, 36)
80 (816, 59)
19 (194, 14)
19 (194, 14)
133 (1,360, 98)
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
19 (194, 14)
49 (500, 36)
74 (755, 55)
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

5.4 (55, 48 in.
lbf)w/ HID:
HID Height
Control Sensor
Front Stabilizer
Bracket No.1 RH
Front Stabilizer
Bracket No.1 LH
96 (979, 71)
80 (816, 59)
52 (530, 38)
± FRONT SUSPENSIONFRONT SUSPENSION
26±5
AVENSIS REPAIR MANUAL (RM1018E)

2600K±06
±
FRONT SUSPENSION FRONT SUSPENSION SYSTEM
26±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
4. Tire (Worn or improperly inflated)
5. Wheel alignment (Incorrect)
6. Steering linkage (Loose or worn)
7. Hub bearing (Worn)
8. Steering gear (Out of adjustment or broken)
9. Suspension parts (Worn)28±1
26±6
±
30±2
51±28
51±36
±
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)±
26±10
26±10
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28±1
26±26
26±10
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loose or worn)
8. Steering gear (Out of adjustment or broken)28±1
28±1
26±10 26±6
26±24
30±2 ±
51±28
51±36
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28±1
26±6
26±10 ±

190O2±01
A79177
± STARTING & CHARGINGGLOW PLUG ASSY (1CD±FTV)
19±33
AVENSIS REPAIR MANUAL (RM1018E)
GLOW PLUG ASSY (1CD±FTV)
REPLACEMENT
1. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
2. REMOVE GLOW PLUG ASSY
(a) Remove the 5 grommets.
(b) Remove the 5 nuts and the glow plug connector.
(c) Remove the 4 glow plugs.
3. INSTALL GLOW PLUG ASSY
Torque:
12.3 N
m (125 kgf
cm, 9 ft
lbf) for glow plug
2.2 N
m (22 kgf
cm, 19 in.
lbf) for nut
4. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)

190JF±02




A34838
19±32
± STARTING & CHARGINGPRE±HEATING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT GLOW PLUG RELAY ASSY
(a) Using an ohmmeter, check for continuity between each
terminal.
Specified condition:
No continuity
1 ± 2Continuity
(Apply battery voltage terminals 3 and 4)

190JE±02
A82619
Light Lightning Time
Water Temperature ±20 0 28 0
±4 32 (
F) (
C)
82.4 (sec.)
10
3
1
A72562
Pre±heating Time (sec)Battery Voltage [V]
A80155
After Glow Time
Water Temperature68 104 (
F) 020 40(
C) (sec.)
1 19±30
± STARTING & CHARGINGPRE±HEATING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRE±HEATING SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
NOTICE:
Turn the ignition switch OFF for 60 seconds before performing the following inspections.
1. INSPECT LIGHTING DURATION OF GLOW INDICA-
TOR LIGHT
(a) Turn the ignition switch ON, and measure the lighting
duration.
Light lighting duration: Refer to the chart graph
2. INSPECT PRE±HEATING
(a) Turn the ignition switch ON, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
(b) Turn the ignition switch STA, check that the battery volt-
age applied to the glow plugs.
SST 09082±00030, 09083±00150
(c) While cranking the engine, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
3. INSPECT AFTER GLOW TIME
(a) After the engine starting, measure how long it takes to the
battery voltage is applied to the terminal SREL of the
ECM.
After glow time: Refer to the chart graph

B08263
Ohmmeter
Continuity
± STARTING & CHARGINGPRE±HEATING SYSTEM (1CD±FTV)
19±31
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT GLOW PLUGS
(a) Using an ohmmeter, check that there is continuity be-
tween the glow plug terminal and ground.
Standard resistance: Approx. 0.72
at 20C (68F)
NOTICE:

Be careful not to damage the glow plug pipes as it
could cause an open circuit or shorten life of the glow
plugs.

Avoid getting oil and gasoline on the glow plug when
cleaning.

Wipe up any oil on the terminal and Bakelite washer
with a dry cloth if they are stained with oil during in-
spection.

Be careful not to apply more than 11 V to the glow plug
as it could cause an open circuit.

190O1±01
A79176
±
STARTING & CHARGING GENERATOR ASSY(1CD±FTV)
19±29
AVENSIS REPAIR MANUAL (RM1018E)
GENERATOR ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
7.REMOVE GENERATOR V BELT (See page 14±269)
8.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
9.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
10.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
11.REMOVE GENERATOR ASSY
(a)Remove the bolt and disconnect the wire harness.
(b)Remove the cap and nut, disconnect the generator wire.
(c)Disconnect the generator connector.
(d)Remove the 2 bolts and the generator.
12.INSTALL GENERATOR ASSY Torque:
31 N
m (320 kgf
cm, 23 ft
lbf) for M8
47 N
m (475 kgf
cm, 34 ft
lbf) for M10
9.8 N
m (100 kgf
cm, 7 ft
lbf) for Generator wire
5.0 N
m (51 kgf
cm, 44 ft
lbf) for Wire harness
13.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
14.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
15.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
16. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±286)
17. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18. CHECK FOR EXHAUST GAS LEAKS

190NN±01
A81051
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow 19±26
± STARTING & CHARGINGCHARGING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY SPECIFIC GRAVITY
(MAINTENANCE TYPE BATTERY)
(a) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20
C (68
F)
HINT:
If the specific gravity is less than specification, charge the bat-
tery.
3. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20
C (68
F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
(Non maintenance type battery)
HINT:
Indicator colorConditionType AType BCondition
GreenBlueGood
DarkWhiteCharging necessary
Clear or light yellowRedReplace
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.

B00543
B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter
± STARTING & CHARGINGCHARGING SYSTEM (1CD±FTV)
19±27
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
6. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
7. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engine is running.
8. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine and check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
9. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-
ter and voltmeter as shown in the illustration.
(1) Disconnect to the wire from terminal B of the gener-
ator and connect it to the negative (±) lead of the
ammeter.
(2) Connect the positive (+) lead of the ammeter to ter-
minal B of the generator
(3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (±) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm, check the
reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 to 14.8 V