width TOYOTA AVENSIS 2005 Service Owner's Manual

H42620
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±33
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the instrument panel passenger airbag assy
(See page 60±29).
CAUTION:

When removing the instrument panel passenger air-
bag assy, work must be started 90 seconds after the
ignition switch is turned to the ºLOCKº position and
the negative (±) terminal cable is disconnected from
the battery.

When storing the instrument panel passenger airbag
assy, keep the upper surface of the airbag deploy-
ment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie down the instrument panel passenger airbag assy to the
tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the instrument panel passenger airbag
assy, it may be snapped by the shock when the airbag is
deployed. This is highly dangerous. Always use a wire har-
ness for vehicle use which has a diameter of at least 1.25
mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the instrument panel passenger airbag assy in-
side the tire with the airbag deployment side facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the instrument panel passenger airbag assy
coming free due to the shock from the airbag deploy-
ment.

Always tie down the instrument panel passenger air-
bag assy with the airbag deployment side facing in-
side the tire.

H42646
Inner
Diam.
Width
Tire
H43004
SST(s)
H42647
Tires
(5 or more) 60±34
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL PASSENGER AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s).
Connect the connector of the SST(s) to the instrument
panel passenger airbag assy.
SST 09082±00780
(e) Place tires.
(1) Place at least 2 tires under the tire to which the
instrument panel passenger airbag assy is tied.
(2) Place at least 2 tires over the tire to which the instru-
ment panel passenger airbag assy is tied. The top
tire should have the disc wheel installed.
NOTICE:
Do not place the SST(s) connector under the fire because
the SST connector could be damaged.

710CN±02
I34628
C10±19
C10±5
± INSTRUMENT PANEL/METERCOMBINATION METER
71±3
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT SPEEDOMETER
(a) Check the operation.
(1) Using a speedometer tester, inspect the speedometer for acceptable indication error and check
the operation of the odometer.
Reference: km/h (Europe)
Standard indicationAcceptable range
20 km/h21.0 ± 25.0 km/h
40 km/h41.7 ± 46.2 km/h
60 km/h62.7 ± 67.2 km/h
80 km/h83.4 ± 88.4 km/h
100 km/h104.3 ± 109.3 km/h
120 km/h125.1 ± 130.6 km/h
140 km/h145.8 ± 151.8 km/h
160 km/h166.2 ± 173.2 km/h
180 km/h186.9 ± 194.5 km/h
200 km/h207.7 ± 215.7 km/h
220 km/h228.4 ± 236.8 km/h
240 km/h249.2 ± 258.0 km/h
Reference: MPH (Europe)
Standard indicationAcceptable range
20 mph21.0 ± 23.5 mph
40 mph42.0 ± 44.5 mph
60 mph62.5 ± 66.0 mph
80 mph83.1 ± 87.1 mph
100 mph103.9 ± 108.4 mph
120 mph124.7 ± 129.6 mph
140 mph145.4 ± 150.7 mph
NOTICE:
Tire wear and over or under inflation will affect the indication error.
(2) Check the deflection width of the speed meter indicator.
Reference: Below 0.5 km/h (0.3 mph)
2. INSPECT OUTPUT SIGNAL OF VEHICLE SPEED
(a) Check for the signal.
(1) While driving the vehicle at the speed of 10 km/h,
check the voltage between the terminal C11±15 of
the combination meter assy and the body ground.
Standard: Fluctuation between 10 to 14 V or less is re-
peated 7 times within 1 sec.
NOTICE:
Check it with the ignition switch ON and the connector con-
nected.

± INTRODUCTIONTERMS
01±9
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O2SOxygen Sensor
O/DOverdrive
OEMOriginal Equipment Manufacturing

A14180
A77457
Width
A775021.0 to 1.4mm45

30

± ENGINE MECHANICALCYLINDER HEAD ASSY
14±41
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
8. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust
ports and cylinder surface for cracks.
9. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360
around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 to 1.4 mm
(0.039 to 0.055 in.).
10. REPAIR VALVE SEATS
NOTICE:
Releasing the seat±cutter pressure gradually helps to
make smoother valve seat faces.
(a) Using a 45
cutter, cut valve face of the cylinder head a
little wider than the specified valve seating width.
(b) Confirm that the valve fits the valve seat center portion.
If not, re±cut the valve face with the 45
cutter.
(c) Adjust valve face with a 30
or 60
cutter to accurately fit
the valve seat center portion.
(1) If the seating is too high on the valve face, use 30

and 45
cutters to correct the seat.

D03807
SST
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
C50259
C
C
C
CA
AA B
BB
C83145
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±59
U241E A/T REPAIR MANUAL (RM840U)
115. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST and a press, install the U/D cylindrical roller
bearing.
SST 09950±60020 (09951±00810), 09950±70010
(09951±07100)
NOTICE:
Do not apply excessive pressure to it.
116. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surfaces of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
(c) Install the transaxle housing and 16 bolts to the transaxle
case.
Torque:
Bolt A: 22 N
m (226 kgf
cm, 16 ft
lbf)
Bolt B and C: 29 N
m (300 kgf
cm, 22 ft
lbf)
HINT:
Apply seal packing or equivalent to the bolt A.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
new bolts and tighten them within 10 minutes after applica-
tion.
117. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install 2 new O±rings to the 2 transaxle case No. 1 plugs.
(b) Install the 2 transaxle case No. 1 plugs to the transaxle
housing.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

A57490
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
A13365
EM0183A57491
Width
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±31
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
7. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side 0.08 mm (0.0031 in.)
Intake manifold side 0.08 mm (0.0031 in.)
Exhaust manifold side 0.08 mm (0.0031 in.)
8. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the intake ports, exhaust
ports and cylinder surface for cracks.
9. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360
around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360
around the valve sat, the guide
and face are concentric. If not, resurface the seat.
(3) Check that the sat contact is in the middle of the
valve face with the width between 1.0 ± 1.4 mm
(0.039 ± 0.055 in.).

EM2534
A62785
Margin
Thickness
EM2534
A62785
Margin
Thickness
A62786
Width
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±31
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT INTAKE VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.65 mm (3.4902 in.)
Minimum overall length: 88.35 mm (3.4784 in.)
(b) Using a vernier calipers, check the valve head margin
thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
16. INSPECT EXHAUST VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.69 mm (3.4917 in.)
Minimum overall length: 88.39 mm (3.4799 in.)
(b) Using a vernier calipers, check the valve head margin
thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360around the face, the valve is
concentric. If not, replace the valve.

A62787
1.0 ± 1.4 mm30
45

A62788
1.0 ± 1.4 mm60

45

P16860
A01080
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 ± 1.4 mm
(0.039 ± 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 30
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75
and 45

cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 ± 30.976 mm (1.2191 ±1.2195 in.)
20. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 ± 31.025 mm (1.2205 ± 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 ± 0.059 mm (0.0009 ± 0.0023 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)

A62821
Seal Width 4 ± 5 mm
6 mmSeal Packing
A62822
SST
A62817SST
14±14
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
42. INSTALL OIL PAN SUB±ASSY
(a) Remove any old packing material from the contact sur-
face.
(b) Apply seal packing in the shape of bead (Diameter 3.5
mm ± 4.5 mm(0.1379±0.177in)) consequently as shown
in the illustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not put into engine oil within 2 hours after instal-
ling.
(c) Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
43. INSTALL OIL PAN DRAIN PLUG
(a) Place a new gasket on the oil pan drain plug, and install it.
Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
44. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off foreign materials.
(b) Using SST, tap in the oil seal until its surface is flush with
the oil seal retainer edge.
SST 09223±15030, 09950±70010 (09951±07100)
NOTICE:
Wipe off extra grease on the crank shaft.
45. INSTALL OIL FILTER UNION
(a) Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
46. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501