belt TOYOTA AVENSIS 2005 Service Owner's Guide

031HN±01
± SERVICE SPECIFICATIONSSEAT
03±71
AVENSIS REPAIR MANUAL (RM1018E)
SEAT
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FRONT SEAT
Seat Inner belt assy x Seat adjuster assy4242831
Seatback cover bracket x Seat adjuster assy (w/ Side airbag)6.06153 in.
lbf
Seat assy x Body3737527
Seat position airbag sensor x Seat adjuster assy8.08271 in.
lbf
Power seat motor assy (Reclining) x Seat adjuster assy4.54640 in.
lbf
Power seat motor assy (Slide) x Seat adjuster assy Bolt
Nut4.0
3.541
3635 in.
lbf
31 in.
lbf
Power seat motor assy (lifter) x Seat adjuster assy Bolt
Nut2.5
2525
25522 in.
lbf
18
Power seat motor assy (Front vertical) x Seat adjuster assy Bolt
Nut2.5
2525
25522 in.
lbf
18
Front seatback spring assy x Front seat adjuster2525518
REAR SEAT
Armrest assy x Seatback assy8.08271 in.
lbf
Seat belt assy outer center x Seatback frame4242831
Seat belt assy outer center x Body4242831
Seatback lock assy x Seatback frame3030622
Seatback hinge x Seatback frame1818513
Seatback hinge x Body1818513
Seatback hinge center x Body1818513
Seatback hinge center x Seatback frame1818513
Side seatback assy x Body1818513
Bench type seatback assy x Body1818513
Seat cushion frame x Body1818513

031H8±01
03±64
± SERVICE SPECIFICATIONSSEAT BELT
AVENSIS REPAIR MANUAL (RM1018E)
SEAT BELT
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FRONT SEAT BELT
Front seat outer belt assy RH (Upper bolt) x Body7.576.566 in.
lbf
Front seat outer belt assy RH (Lower bolt) x Body4243031
Front seat inner belt assy RH x Front seat assy4243031
Front shoulder belt anchor adjuster assy x Body4243031
Front seat outer belt (Floor anchor side) x Body4243031
Front seat outer belt (Shoulder anchor side) x Body4243031
REAR SEAT BELT
Rear seat 3 point type belt assy inner x Body4243031
CRS anchor bracket sub±assy RH x Body3131623
Rear seat belt assy outer center (Retractor side) x Body4243031
Rear seat belt assy outer center (Floor anchor side) x Body4243031
Rear seat 3 point type belt assy outer (Upper bolt) x Body7.576.566 in.
lbf
Rear seat 3 point type belt assy outer (Lower bolt) x Body4243031
Rear seat 3 point type belt assy outer (Floor anchor side) x Body4243031

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

031HH±01
± SERVICE SPECIFICATIONSHEATER AND AIR CONDITIONING
03±61
AVENSIS REPAIR MANUAL (RM1018E)
HEATER AND AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume Standard:440
30 g (15.51
1.06 oz.)
Belt deflection New belt:
Used belt:11 ± 13 mm (0.43 ± 0.51 in.)
13.5 ± 16.5 mm (0.53 ± 0.64 in.)

±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
05±79
AVENSIS REPAIR MANUAL (RM1018E)
12CHECK VALVE CLEARANCE OF MISFIRING CYLINDER (See page 14±6)
NGADJUST VALVE CLEARANCE
OK
13SWITCH STEP BY NUMBER OF MISFIRE CYLINDER(REFER RESULT OF STEP 4)
High Misfire Rate CylinderProceed to
1 or 2 cylindersA
More than 3 cylindersB
BCHECK FOR INTERMITTENT PROBLEMS
A
14CHECK VALVE TIMING(CHECK FOR LOOSE AND JUMPING TEETH OF TIMING BELT) (See page 14±49)
NGADJUST VALVE TIMING
OK
15CHECK FUEL PRESSURE (See page 11±5)
NG CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
16 READ VALUE OF HAND±HELD TESTER(INTAKE AIR TEMPERATURE AND MASS AIR FLOW RATE)
(a) Connect the hand±held tester to the DLC3.
(b) Turn the ignition switch ON.
(c) Check the intake air temperature.
(1) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / INTAKE AIRº and read its valuedisplayed on the hand±held tester.
Temperature: Equivalent to ambient temperature
(d) Check the air flow rate. (1) Select the item ºDIAGNOSIS / OBS/MOBD / DATA LIST / ALL / MAFº and read its value displayedon the hand±held tester.
Standard:
ConditionAir flow rate (gm/s)
Ignition switch On (do not start engine)0
Idling4 to 6
Running without load (2,500 rpm)13 to 20
Idling ± RunningAir flow rate fluctuates

05±546
±
DIAGNOSTICS ECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E) P0380
(05±622)
Glow Plug/Heater Circuit ºAº

Open or short in glow plug circuit

Glow fuse

Glow relay

Glow plug

ECM

P0400
(05±629)Exhaust Gas Recirculation Flow
EGR valve assy

EGR passage
P0403
(05±629)Exhaust Gas Recirculation Con-
trol Circuit
EGR assage

Open or short in EGR circuit

ECM
P0488
(05±633)Exhaust Gas Recirculation
Throttle Position Control Range/
Performance
Open or short in intake shutter circuit

Open or short in fully opened switch circuit

Intake shutter

ECM

P0500
(05±640)Vehicle Speed Sensor ºAº

Open or short in speed sensor circuit

Speed sensor

Combination meter

ECM

Skid control ECU

P0504
(05±643)Brake Switch ºAº/ºBº Correlation

Short in stop lamp switch signal circuit

Stop lamp switch

ECM


P0560
(05±647)System Voltage
Open in back±up power source circuit

ECM
P0606
(05±650)ECM/PCM Processor

ECM



P0607
(05±650)Control Module Performance

ECM

P0622
(05±651)Generator Field ºFº Terminal Cir-
cuit

Open in generator circuit

Generator

Drive belt

ECM

P0627
(05±655)Fuel Pump Control Circuit / Open

Open or shot in suction control valve circuit

Suction control valve

ECM

P1229
(05±563)Fuel Pump System

Short in supply pump (suction control valve) circuit

Suction control valve

ECM

P1238
(05±658)Injector Malfunction

Injector

EDU (P0200 is set simultaneously)

Open or short in engine wire (P0200 is set simultaneously)

Connector connection (P0200 is set simultaneously)

Compression pressure

Valve clearance

Valve timing

ECM

P1251
(05±612)Turbo/Super Charger Overboost
Condition (Too High)

VRV

Open or short in VRV circuit

Turbocharger

EGR valve

Vacuum hose

ECM

P1271
(05±663)Fuel Regulator Circuit Malfunc-
tion (EDU Drive)

Open or short in pressure discharge valve circuit

Open or short in pressure discharge valve it self

EDU

ECM

P1272
(05±663)Fuel Pressure Regulator Mal-
function

Open or short in pressure discharge valve circuit (P1271 is set
simultaneously)

Pressure discharge valve

Supply pump

ECM


A81017
GeneratorGlow Plug ECMGLOW
Relay Battery
± DIAGNOSTICSECD SYSTEM (1CD±FTV)
05±651
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0622 GENERATOR FIELD ºFº TERMINAL CIRCUIT
CIRCUIT DESCRIPTION
While the generator is generating the current, the duty signal is sent from terminal M of the generator to the
ECM terminal ALT. The duty signal is used for detecting the open malfunction of the generator circuit and
DTC P0380.
DTC No.DTC Detection ConditionTrouble Area
P0622Generator terminal M duty signal is not output while engine is
running.

Open in generator circuit

Generator

Driver belt

ECM
MONITOR DESCRIPTION
The ECM will detect a generator failure or an open malfunction of the circuit, if the duty signal is not output
from terminal M of the generator despite the engine running.
MONITOR STRATEGY
Required sensorsGenerator circuit
Frequency of operationContinuous
Duration10 sec.
CHK ENG operation1 driving cycle
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
Battery voltage11 V±
Engine speed700 rpm2,000 rpm
TYPICAL MALFUNCTION THRESHOLDS
Threshold
There is no signal output from terminal M of the generator
05CQ7±01

A80456
E13
ALTECM Connector
A81490
A11
Wire Harness Side
Generator Connector
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±653
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
HINT:

If different DTCs related to different systems that have terminal E2 as the ground terminal are output
simultaneously, terminal E2 may be open.

Read freeze frame data using \b
 . Freeze frame data records the engine conditions
when a malfunction is detected. When troubleshooting, it is useful for d\
etermining whether the vehicle
was running or stopped, the engine was warmed up or not, etc. at the time o\
f the malfunction.
1CHECK IF CHARGE LAMP IS ILLUMINATED
HINT:
Run the engine at 2,000 rpm, and check if the charge lamp located in the\
combination meter is OFF.
YESGo to step 3
NO
2CHECK HARNESS AND CONNECTOR(GENERATOR ± ECM)
(a)Disconnect the E13 ECM connector.
(b)Disconnect the A11 generator connector.
(c)Check for continuity between the wire harness side con- nector.
Standard (Check for open):
Symbols (Terminal No.)Specified condition
ALT (E13±8) ± M (A11±3)Continuity
Standard (Check for short):
Symbols (Terminal No.)Specified condition
ALT (E13±8) or M (A11±3) ± Body groundNo continuity
NGREPAIR OR REPLACE HARNESS OR CONNECTOR
OK
3INSPECT DRIVE BELT (See page 14±266)
NG REPAIR OR REPLACE DRIVE BELT (See page 14±269)
OK

050TM±13
05±1100
±
DIAGNOSTICS AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
If the normal code is displayed during DTC check although the problem still occurs, check the circuits for
each problem symptom in the order given in the table below, and proceed to the relevant troubleshooting.
SymptomSuspect AreaSee page
Whole functions of the A/C system does not operate.
1. IG power source circuit
2. A/C amplifier assy
3. Engine ECU 1AZ±FSE: 1AZ±FE:
1ZZ±FE/3ZZ±FE:
1CD±FTV:05±1144
05±1098 05±294
05±149 05±5
05±528
Air Flow Control : No blower operation
1. Blower motor circuit
2. Heater relay circuit
3. Blower w/fan motor sub±assy
4. A/C amplifier assy05±1148
05±1146
05±1148
05±1098
Air Flow Control : No blower control1. Blower motor circuit05±1148
Air Flow Control : Insufficient air out
1. Blower w/fan motor sub±assy
2. Blower motor circuit
3. A/C amplifier assy05±1148
05±1148
05±1098
Temperature Control : Cool air does not come out
1. Volume of refrigerant
2. Drive belt tension
3. Refrigerant pressure
4. Air conditioner magnetic valve circut
5. Pressure sensor circuit
6. Air mix control servomotor circuit
7. Air mix damper position sensor circuit
8. Room temp. sensor circuit
9. Ambient temp. sensor circuit
10.A/C amplifier assy55±24
55±46
55±24
05±1151 05±1116
05±1133
05±1122
05±1102
05±1106
05±1098
Temperature Control : Warm air does not come out
1. Air mix control servomotor circuit
2. Air mix damper position sensor circuit
3. Ambient temp. sensor circuit
4. Room temp. sensor circuit
5. A/C amplifier assy
6. Heater radiator05±1133
05±1122
05±1106
05±1102
05±1098
±
Temperature Control : Output air is warmer or cooler than the set
temperature or response is slow.
1. Room temp. sensor circuit
2. Ambient temp. sensor circuit
3. Solar sensor circuit
4. Air mix damper position sensor circuit
5. Air mix control servomotor circuit
6. Evaporator temp. sensor circuit
7. A/C amplifier assy05±1102
05±110605±1113
05±1122
05±1133
05±1109
05±1098
Temperature Control : No temperature control (only Max. cool or Max. warm)
1. Room temp. sensor circuit
2. Ambient temp. sensor circuit
3. Solar sensor circuit
4. Air mix damper position sensor circuit
5. Air mix control servomotor circuit
6. Evaporator temp. sensor circuit
7. A/C amplifier assy05±1102
05±1106
05±1113
05±1122
05±1133
05±1109
05±1098
No air inlet control1. Recirculation damper servomotor circuit
2. A/C amplifier assy05±1153
05±1098
No air outlet control
1. Air outlet damper position sensor circuit
2. Air outlet control servomotor circuit
3. A/C amplifier assy05±1126
05±1136
05±1098

I35419
A10A9
± DIAGNOSTICSAIR CONDITIONING SYSTEM
05±1099
AVENSIS REPAIR MANUAL (RM1018E)Terminal No. (Symbols)Specification Condition Wiring Color
A16±22 (TR) ±
A16±6 (SG±5)GR ± GIG SW: ON
Cabin temp.: 25
C (77
F)
40
C (104
F)1.8 to 2.2
1.2 to 1.6 V
A16±10 (TE) ±
A15±16 (SG±4)B ± W±GEvaporator temp.: 0
C (32
F)
15
C (59
F)2.0 to 2.4
1.4 to 1.8 V
A16±23 (ILL+) ±
A16±13 (GND)G ± W±BLight control switch TAIL or HEAD10 to 14 V
A16±19 (TPM) ±
A15±15 (SG±3)GR±R ± G±WIG SW: ON
Set air flow setting: DEF.
FACE1.0
4.0 V
A15±8 (SOL+) ±
A16±13 (GND)R ± W±BStart engine
Compressor: OperatePulse generation
A15±7 (MGV) ±
A16±13 (GND) (*1)R±Y ± W±BStart engine
Hot gas heater: Operate10 to 14
Below 1.0 V
A16±11 (HOTGASIN) ±
A16±13 (GND) (*1)G±Y ± W±BIG SW: ON
Hot Gas SW: ON10 to 14 V
A16±16 (S5) ±
A16±18 (SG)B±W ± G±WIG SW: LOCK
ON0
5.0 V
A16±1 (S5±1) ±
A15±13 (SG±1)R ± PIG SW: LOCK
ON0
5.0 V
A16±2 (S5±2) ±
A15±14 (SG±2)Y±B ± Y±RIG SW: LOCK
ON0
5.0 V
A16±14 (S5±3) ±
A15±15 (SG±3)BR±W ± G±WIG SW: LOCK
ON0
5.0 V
A16±15 (S5±4) ±
A16±9 (TSD)O ± LGIG SW: LOCK
ON1.7
4.2 V
A16±15 (S5±4) ±
A16±21 (TSP)O ± LIG SW: LOCK
ON1.7
4.2 V
A15±17 (CFAN) ±
A16±13 (GND)W±R ± W±BStart engine
Condenser fan: operate10 to 14
Below 1.0 V
A16±19 (PBKIG) ±
A17±13 (GND)B±W ± W±BIG SW: ON
PARKING BRAKE SW: OFF
ON10 to 14
Below 1.0 V
A17±3 (PBLT) ±
A17±13 (GND) (*3)L±R ± W±BIG SW: ON
SEAT BELT SIGNAL: OFF
ON10 to 14
Below 1.0 V
A17±4 (RDEFIN) ±
A17±13 (GND) (*2)G±W ± W±BIG SW: ON
RDEF RELAY : OFF
ONBelow 1.0
10 to 14 V
(*1) Diesel (standard) only
(*2) Petrol only
(*3) Except 1AZ±FE
2. COMBINATION METER
Terminal No. (Symbols)Wiring ColorConditionSpecification
C10±17 (Z1H) ±
Body groundW±B ± Body groundAlwaysContinuity
C10±11 (HAY) ±
C10±12 (HAZ)W±R ± WIG SW: ON
Ambient temp.: 25
C (77
F)
40
C (104
F)1.35 to 1.75

0.85 to 1.25 V