TOYOTA AVENSIS 2005 Service Repair Manual

01±14
± INTRODUCTIONTERMS
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E) TCM
Transmission Control ModuleTransmission ECU, ECT ECU
TPThrottle PositionThrottle Position
TRTransmission Range±
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree±Way Catalytic Converter
Three±Way Catalytic (TWC)
Manifold Converter
CC
RO
TWC+OCThree±Way + Oxidation Catalytic ConverterCCR + CCo
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor
WOTWide Open ThrottleFull Throttle
WU±OCWarm Up Oxidation Catalytic Converter±
WU±TWCWarm Up Three±Way Catalytic Converter±
3GRThird Gear±
4GRFourth Gear±

010B9±09
± INTRODUCTIONTERMS
01±7
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger

01±8
± INTRODUCTIONTERMS
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Camshaft
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
DVDDigital Versatile Disc
EBDElectric Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECTElectronic Control Transmission
ECUElectronic Control Unit
EDElectro±Deposited Coating
EDUElectronic Driving Unit
EDICElectric Diesel Injection Control
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
EGR±VMEGR±Vacuum Modulator
ELREmergency Locking Retractor
EMPSElectric Motor Power Steering
ENGEngine
ESAElectronic Spark Advance
ETCS±iElectronic Throttle Control System±intelligent
EVAPEvaporative Emission Control
EVPEvaporator
E±VRVElectric Vacuum Regulating Valve
EXExhaust
FEFuel Economy
FFFront±Engine Front±Wheel±Drive
F/GFuel Gauge
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
F/WFlywheel
FW/DFlywheel Damper
FWDFront±Wheel±Drive
GASGasoline
GNDGround
GPSGlobal Positioning System
HACHigh Altitude Compensator
H/BHatchback
H±FUSEHigh Current Fuse

± 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

01±10
± INTRODUCTIONTERMS
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free±Tronic

± INTRODUCTIONTERMS
01±11
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)Abbreviations Meaning
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRCTraction Control System
TURBOTurbocharge
TWCThree±Way Catalyst
U/DUnderdrive
U/SUndersize
VCVVacuum Control Valve
VENTVentilator
VINVehicle Identification Number
VPSVariable Power Steering
VSCVehicle Stability Control
VSVVacuum Switching Valve
VTVVacuum Transmitting Valve
VVT±iVariable Valve Timing±intelligent
w/With
WGNWagon
W/HWire Harness
w/oWithout
WU±TWCWarm Up Three±way Catalytic Converter
WU±OCWarm Up Oxidation Catalytic Converter
1stFirst
2ndSecond
2WDTwo Wheel Drive Vehicle (4 x 2)
3rdThird
4thFourth
4WDFour Wheel Drive Vehicle (4 x 4)
4WSFour Wheel Steering System
5thFifth

141BV±01
A77366
Intake Valve Guide Bush

Non±reusable part
Valve Stem Oil O Seal or RingValve Lifter
Valve Retainer Lock
Retainer
Inner Compression Spring
Valve Spring Seat
Exhaust Valve Guide Bush
Stud Bolt
Cylinder Head Assy
Intake Valve Exhaust Valve Ring w/ Head Pin
14±38
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
CYLINDER HEAD ASSY
COMPONENTS

190OI±01
A81555
A82635
A82636
A82637
19±2
± STARTING & CHARGINGSTARTER ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
OVERHAUL
1. REMOVE REPAIR SERVICE STARTER KIT
(a) Remove the nut, and disconnect the lead wire from the re-
pair service starter kit.
(b) Remove the 3 nuts holding the repair service starter kit to
the starter housing.
(c) Remove the repair service starter kit.
(d) Remove the return spring and plunger.
2. REMOVE STARTER YOKE ASSY
(a) Using a torx driver T25, remove the 2 through bolts and
pull out the starter yoke together with the starter commu-
tator end frame.
(b) Remove the starter yoke from the starter commutator end
frame.
3. REMOVE STARTER ARMATURE ASSY
(a) Remove the starter armature assy from the starter yoke assy.

A79722
A82638
A82639
A82640
A82641
Terminal C
Terminal 50Continuity
± STARTING & CHARGINGSTARTER ASSY
19±3
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
4. REMOVE STARTER ARMATURE PLATE
(a) Remove the armature plate from the starter yoke.
5. REMOVE STARTER BRUSH HOLDER ASSY
(a) Remove the 2 screws and brush holder assy from the
commutator end frame.
6. REMOVE PLANET GEAR
(a) Remove the 3 planet gears from the repair service starter
kit.
7. INSPECT REPAIR SERVICE STARTER KIT
(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly
to its original position.
If necessary, replace the repair service starter kit.
(b) Check the pull±in coil for open circuit.
(1) Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity, replace the repair service starter kit.

A82642
Terminal 50Continuity
A82643
Continuity
A82644No Continuity
A82645
A82646
29mm 19±4
± STARTING & CHARGINGSTARTER ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(c) Check if the hold±in coil has an open circuit.
(1) Using an ohmmeter, check that there is continuity
between terminal 50 and the switch body.
If there is no continuity, replace the repair service kit.
8. INSPECT STARTER ARMATURE ASSY
(a) Check the commutator for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segments, replace the ar-
mature.
(b) Check the commutator for ground.
(1) Using an ohmmeter, check that there is no continu-
ity between the commutator and the armature coil
core.
If there is continuity, replace the armature.
(c) Check the commutator for dirty or burned surface.
If the surface is dirty or burnt, smooth the surface with 400±grit
sandpaper.
(d) Check for the commutator circuit runout.
(1) Place the commutator on V±blocks.
(2) Using a dial indicator, measure the circle runout.
Standard runout: 0.02 mm (0.0008 in.)
Maximum runout: 0.05 mm (0.0020 in.)
If the runout is greater than maximum, replace the armature.
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard length: 29 mm (1.142 in.)
Minimum length: 28 mm (1.102 in.)
If the diameter is less than minimum, replace the armature.