crankshaft TOYOTA AVENSIS 2005 Service Owner's Manual

03±20
± SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Injection pipe, Fuel inlet pipe x Common rail
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
Injection pipe x Injector
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
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
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 x injection pump
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
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214
9015
78 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
V±ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub±assy x V±ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub±assy center x Body4545933
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.
lbf
Fuel filter assy x Fuel filter support1817813

± SERVICE SPECIFICATIONSENGINE MECHANICAL
03±21
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Air cleaner assy x Body x Engine mounting bracket LH7.07162 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
Timing belt tensioner x Cylinder block2121415
Timing chain cover plate x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting bracket x
Cylinder block For 14 mm head bolt
For 17 mm head bolt
37
64375
65027
47
Timing belt No. 1 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 1 cover x Oil pump assy7.47565 in.
lbf
Timing belt No. 2 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 2 cover x Cylinder head cover sub±assy7.47565 in.
lbf
Timing belt No. 2 cover x Camshaft oil seal retainer7.47565 in.
lbf
Timing belt No. 2 cover x Timing belt cover No. 37.47565 in.
lbf
Crankshaft pulley x Crankshaft1801,835133
Engine mounting bracket No.2 RH x Transverse engine
engine mounting bracket5253038
Camshaft bearing cap x Cylinder head2020415
Camshaft oil seal retainer x Cylinder head8.89078 in.
lbf
Camshaft timing pulley x Camshaft8889965
Cylinder head cover x Cylinder head131359.7
Vacuum reservoir sub±assy x Cowl top panel outer8.38573 in.
lbf
Cylinder head x Cylinder block4545933
Drain plug (oil pan)3435025

031DZ±02
03±6
± SERVICE SPECIFICATIONSENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle position sensor x Throttle body assy2.02018 in.
lbf
ISC valve x Throttle body assy3.73833 in.
lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold9.09280 in.
lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.
lbf
Wire harness protector x Throttle body bracket8.48674 in.
lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Accelerator pedal x Body5.45548 in.
lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.
lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.
lbf
Crankshaft position sensor x Oil pump assy8.89079 in.
lbf
ECM x Body5.55649 in.
lbf

±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
03±5
AVENSIS REPAIR MANUAL (RM1018E)
1CD±FTV:
Mass air flow meter
Resistance2 (THA) ± 1 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
12.5 to 16.9 k 
2.19 to 2.67 k 
0.50 to 0.68 k 
Intake shutter assy
Resistanceat 20
C (68
F)
2 ± 1, 3
5 ± 4, 6
18 to 22 
18 to 22 
Accelerator pedal assy (See page 10±56)
Resistance VPA1 ± EP1
VPA2 ± EP2
VCP1 ± EP1
VCP2 ± EP2
5.0 k or less
5.0 k or less
1.5 to 6.0 k 
1.5 to 6.0 k 
Diesel turbo inlet air temperature sensor
Resistance Approx. 20
C (68
F)
2.21 to 2.65 k 
Crankshaft position sensor
Resistance at cold
at hot
1630 to 2740 
2065 to 3225 
Camshaft position sensor
Resistance at cold
at hot
1630 to 2740 
2065 to 3225 
Diesel engine engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k 
0.310 to 0.326 k 
Injection or supply pump assy
Resistance THF ± E2
Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.21 to 2.69 k 
0.287 to 0.349 k 

031E5±01
± SERVICE SPECIFICATIONSIGNITION
03±31
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1818413
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf
Cord clamp x Timing chain cover sub±assy9.09280 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1919414
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf

031E4±01
03±30
± SERVICE SPECIFICATIONSIGNITION
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Spark plug
Recommended spark plug DENSO made
NGK made
Electrode gap K16R±U11, BKR5EYA11
K16R±U11
BKR5EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold
Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance Cold
Hot
1,630 to 2,740

2,065 to 3,225

1AZ±FE:
Spark plug
Recommended spark plug DENSO made
NGK made
Electrode gap K20R±U11, BKR6EYA11
K20R±U11
BKR6EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold
Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance Cold
Hot
985 to 1,600

1,265 to 1,890

1AZ±FSE:
Spark plug
Recommended spark plug DENSO made
Electrode gap SK20BR11
SK20BR11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold
Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance Cold
Hot
985 to 1,600

1,265 to 1,890

± SERVICE SPECIFICATIONSLUBRICATION
03±29
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Oil pan sub±assy x Cylinder block Bolt A
Bolt B
Bolt C
Bolt D42
21
11
12428
214
11 2
12231
15
8
9
Oil pan insulator x Oil pan sub±assy7.57666 in.
lbf
Oil strainer sub±assy x Oil pan sub±assy Bolt
Nut21
13209
13515
10
Oil pan Sub±assy No.2 x Oil pan sub±assy1211 99
Engine oil level sensor x Oil pan sub±assy No.27.07162 in.
lbf
Oil level gage guide x Cylinder block1818413
V±ribbed belt tensioner assy x Oil pump assy3132023
Timing belt idler sub±assy No. 1 x Cylinder head3535726
Timing belt idler sub±assy No. 2 x Oil pump assy4747935
Engine mounting insulator sub±assy RH x Transverse engine engine mount-
ing bracket5253038
Engine mounting insulator sub±assy RH x Body5253038
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel RH1031,05076
Oil cooler assy x Cylinder block4545433

031HI±01
03±62
± SERVICE SPECIFICATIONSHEATER AND AIR CONDITIONING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
Tighten2.52522 in.
lbf
Fully tighten3939029
AIR CONDITIONER RADIATOR ASSY
Air conditioning tube assy x Cooler evaporator sub±assy No. 13.53530 in.
lbf
Air conditioner unit assy x Body9.810087 in.
lbf
BLOWER ASSY
Blower assy x Body Bolt:9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1CD±FTV)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy RHD:9.810087 in.
lbf
Suction servic valve x W/pulley compressor assy LHD:9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x Suction servic valve9.810087 in.
lbf
W/RECEIVER CONDENSER ASSY
Cap x W/receiver condenser assy2.92925 in.
lbf
Magnet valve x W/receiver condenser assy3.43530 in.
lbf
Discharge tube x Magnet valve3.43530 in.
lbf
Discharge tube x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy B x W/receiver condenser assy5.45547 in.
lbf
Discharge hose sub±assy x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy A x W/receiver condenser assy5.45547 in.
lbf
HEAER ASSY
Heater assy x Body7.57666 in.
lbf

05B3M±03
A79104
Fuel Pump
Circuit Opening Relay
ECM
DLC3
Camshaft Position
Sensor
Engine Coolant
Temperature Sensor
Camshaft Timig OIL
Control Valve Assy
Crankshaft
Position Sensor
Knock Sensor
Mass Air Flow Meter Assy
Heated Oxygen Sensor
(Bank 1 Sensor 1)
Engine Room R/B No.1
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Engine Room R/B No.4
Ignition Coil and Igniter
Injector
Power Steering Oil
Pressure Switch
Idle Speed Control
Valve Assy
Throttle Position Sensor
Vacuum Switching Valve
(for ISC)
VSV for EVAP
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±19
AVENSIS REPAIR MANUAL (RM1018E)
LOCATION

±
DIAGNOSTICS SFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±17
AVENSIS REPAIR MANUAL (RM1018E)P0171*
3
(05±67)
System too Lean (Fuel Trim)
(Bank1)


Air induction system

Injector blockage

PCV hose

Mass air flow meter

Engine coolant temperature sensor

Fuel pressure

Open or short in heated oxygen sensor circuit

Heated oxygen sensor

ECM

P0172*3
(05±67)
System too Rich (Fuel Trim)
(Bank1)

Injector leak, blockage

Mass air flow meter

Engine coolant temperature sensor

Ignition system

Fuel pressure

Open or short in heated oxygen sensor circuit

Gas leakage in exhaust system

Heated oxygen sensor

ECM

P0300*3
(05±73)
Random/Multiple Cylinder Misfire
Detected
Open or short in engine wire

Connector connection
Vac m hose connectionP0301*3
(05±73)Cylinder 1 Misfire Detected

Vacuum hose connection

PCV hose

Ignition system
P0302*3
(05±73)Cylinder 2 Misfire Detected

Injector

Fuel pressure

Mass air flow meter

P0303*3
(05±73)Cylinder 3 Misfire Detected

Mass air flow meter

Engine coolant temperature sensor

Compression pressure

Valve clearance
P0304*3
(05±73)Cylinder 4 Misfire Detected

Valve clearance

Valve timing

ECM
P0325
(05±81)Knock Sensor 1 Circuit Malfunc-
tion (Bank 1)
Open or short in knock sensor circuit

Knock sensor (under±torqued or loose)

ECM

P0335
(05±84)Crankshaft Position Sensor ºAº
Circuit Malfunction

Open or short in crankshaft position sensor circuit

Crankshaft position sensor

Crank angle sensor plate

ECM

P0340
(05±88)Camshaft Position Sensor Circuit
Malfunction

Open or short in camshaft position sensor circuit

Camshaft position sensor

Intake camshaft

Timing chain has jumped a tooth

ECM

P0420*3
(05±91)
Catalyst System Efficiency Be-
low Threshold (Bank 1)

Gas leakage in exhaust system

Heated oxygen sensor

Three±way catalytic converter

ECM

P0443
(05±94)Evaporative Emission Control
System Purge Control Vent Cir-
cuit Malfunction
Open or short in VSV for EVAP circuit

VSV for EVAP

ECM

P0500
(05±98)Vehicle Speed Sensor Malfunc-
tion

Open or short in speed sensor circuit

Speed sensor

Combination meter

ECM

Skid control ECU