air filter TOYOTA AVENSIS 2005 Service Repair Manual

± INTRODUCTIONTERMS
01±43
AVENSIS REPAIR MANUAL (RM1018E) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

D01556
WRONG
D01563
01±16
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(±) terminal cable is disconnected. If necessary, be
sure to initialize the system.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless
absolutely necessary (If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity).
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission±re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation and without anything that could cause combustion
around you such as a welder, grinder, drill, electric motor or stove.
(2) Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel
will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operations.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray much water so as to prevent slipping.
(3) Never use any electric equipment like an electric motor or a working light, as they may create
sparks or a high temperature.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of shop rags containing fuel deposits separately.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, this may give a
bad effect to the engine and turbocharger.
(b) When removing and installing the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean waste cloth or gum tape.
(c) When installing the inlet system parts, check that there is
no mixing of a metal tip.

022K9±01
02±20
± PREPARATIONLUBRICATION
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION
PREPARATION
SST
09023±12900Union Nut Wrench 19mmOIL PUMP ASSY(1AZ±FSE)
09032±00100Oil Pan Seal CutterOIL PUMP ASSY(1AZ±FE)
OIL PUMP ASSY(1AZ±FSE)
OIL PUMP ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolOIL PUMP ASSY(1AZ±FE)
OIL PUMP ASSY(1AZ±FSE)
OIL PUMP ASSY(1CD±FTV)
(90105±08076)BoltOIL PUMP ASSY(1CD±FTV)
(91651±60855)BoltOIL PUMP ASSY(1AZ±FE)
OIL PUMP ASSY(1AZ±FSE)
09223±46011Crankshaft Front Oil Seal
ReplacerOIL PUMP ASSY(1CD±FTV)
09228±06501Oil Filter WrenchOIL FILTER SUB±ASSY(1AZ±FE)
OIL FILTER SUB±ASSY(1AZ±FSE)
OIL FILTER
SUB±ASSY(1ZZ±FE/3ZZ±FE)
09228±10002Oil Filter WrenchOIL FILTER SUB±ASSY(1CD±FTV)
09249±63010Torque Wrench AdaptorOIL PUMP ASSY(1AZ±FE)
OIL PUMP ASSY(1AZ±FSE)
09316±60011Transmission & Transfer Bearing
ReplacerOIL PUMP ASSY(1CD±FTV)
(09316±00011)Replacer PipeOIL PUMP ASSY(1CD±FTV)
(09316±00021)Replacer ºAºOIL PUMP ASSY(1CD±FTV)

02±22
± PREPARATIONLUBRICATION
AVENSIS REPAIR MANUAL (RM1018E)
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)OIL PUMP ASSY(1CD±FTV)
Lubricant
ItemCapacityClassification
Oil grade (gasoline engine)
±
API grade SJ ºEnergy±Conservingº, SL ºEnergy±
Conservingº multigrade engine oil or ILSAC multi-
grade engine oil
Oil grade (Diesel engine)±ACEA B1, API CF±4 or CF
(You may also use API CE or CD.)
Drain and refill (1ZZ±FE/3ZZ±FE)
w/ oil filter change
w/o oil filter change
3.7 liters (3.9 US qts, 3.3 lmp. qts)
3.5 liters (3.7 US qts, 3.1 lmp. qts)±
Drain and refill (1AZ±FE/1AZ±FSE)
w/ oil filter change
w/o oil filter change
4.2 liters (4.4 US qts, 3.7 lmp. qts)
4.0 liters (4.2 US qts, 3.5 lmp. qts)±
Drain and refill (1CD±FTV)
w/ oil filter change
w/o oil filter change
5.9 liters (6.2 US qts, 5.2 lmp. qts)
5.3 liters (5.6 US qts, 4.7 lmp. qts)±
Dry fill (1ZZ±FE/3ZZ±FE)4.2 liters (4.4 US qts, 3.7 lmp. qts)±
Dry fill (1AZ±FE/1AZ±FSE)4.9 liters (5.2 US qts, 4.3 lmp. qts)±
Dry fill (1CD±FTV)6.7 liters (7.1 US qts, 5.9 lmp. qts)±

022J6±01
02±4
± PREPARATIONFUEL
AVENSIS REPAIR MANUAL (RM1018E)
FUEL
PREPARATION
SST
09023±12700Union Nut Wrench 17mmINJECTOR ASSY(1CD±FTV)
INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
COMMON RAIL ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(90105±08076)BoltINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09228±64030Fuel Filter WrenchFUEL FILTER ASSY(1CD±FTV)
09268±21010Fuel Hose PullerFUEL INJECTOR ASSY(1AZ±FE)
FUEL PRESSURE PULSATION
DAMPER ASSY(1AZ±FE)
FUEL INJECTOR ASSY
(1ZZ±FE/3ZZ±FE)
09268±41047Injection Measuring Tool SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09268±41110)AdaptorFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09268±41300)ClampFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(95336±08070)HoseFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09280±00010Union Bolt,inspectionINJECTOR ASSY(1CD±FTV)
09330±00021Companion Flange Holding ToolINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09617±24011)Steering Rack WrenchFUEL PUMP ASSY(1AZ±FSE)

02±6
± PREPARATIONFUEL
AVENSIS REPAIR MANUAL (RM1018E)
09082±00040TOYOTA Electrical TesterFUEL SYSTEM(1CD±FTV)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1AZ±FSE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09130±00150Water Pump PliersFUEL FILTER ASSY(1CD±FTV)
09216±00021Belt Tension GaugeINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
Equipment
Clip
Hexagon wrench (6 mm)
Measuring Flask
Ohmmeter
Radiator cap tester
Service Wire Harness
Stopwatch
Torque wrench
Vernier calipers
Wooden block
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)INJECTOR ASSY(1CD±FTV)
08850±00065Butyl Tape SetFUEL TANK ASSY(DIESEL)

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 SPECIFICATIONSFUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Injection pipe clamp No. 2 x Intake manifold5.05144 in.
lbf
Fuel inlet pipe sub±assy x Common rail assy
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 sub±assy x Injection pump assy
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
Air cleaner case x Body7.07162 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket7.07162 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
Vacuum reservoir sub±assy x Cowl top panel outer8.38574 in.
lbf
Injection pump assy x Water pump assy2121015
Injection pump drive pulley x Injection pump assy6465047
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Common rail assy x Cylinder head sub±assy4343832
Transverse engine engine mounting bracket x Water pump assy6465047
Transverse engine engine mounting bracket x Cylinder block sub±assy3737527
Idler pulley sub±assy x V±ribbed belt tensioner assy4040830
Battery clamp sub±assy x Body5.05144 in.
lbf
Front wheel1031,05076
Fuel filter assy x Fuel filter support1817813
DIESEL:
Part TightenedN
mkgf
cmft
lbf
Fuel tank band sub±assy x Body4040029
Parking brake cable assy x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Body5.45548 in.
lbf
Fuel tank protector No. 1 x Fuel tank band sub±assy No. 15.45548 in.
lbf

±
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

A79094
*1: LHD
*2: RHD
*3: SEDAN
*4: LIFT BACK
*5: WAGON IE36
IR11 G±W
(*1)
G±W
(*2)G±W
G±W(*1)
(*2)
1
2DA DC
DM
1 210Driver Side J/B
E10STPECM
19
G±W
G±W
G±WG±W
G±W
G±W
G±W
G±W J30 C
BJ30 J30
J31
J31
B CC
2
1 R±W
IR1 2 IE3 11
DA22
STOP
DN1Driver
Side J/BCH20
High Mounted
Stop Light
J32
Junction
Connector W±B (*1)(*2) R±W
R±W
(*1)(*2) R±W(*3)
(*3)
C(*4, *5)
(*4, *5)
(*4, *5)
(*4)
(*5)
6 4 1
6 5 21 4 7
3 3 6 (*3)
(*4)
(*5)(*3)
(*4)
(*5)
(*3)
(*4)
(*5)(*3)
(*4)
(*5) R13
Rear
Combination
Light LHR14
Rear
Combination
Light RH Junction
ConnectorN8
Noise
FilterBD1 1
BF1 3
BE1 1L
G±W
G±W
1
2 H20
High
Mounted
Stop Light(*4)
(*4)(*5)
L
W±B
W±B (*4)(*5)
(*5)
(*4) (*4)
(*5)
(*4) (*5)
(*5)(*4, *5) W±B W±B
W±B
W±BW±B W±B
(*3)
W±B
(*3)W±B W±B
W±B
(*4, *5)
W±B Junction
Connector
Junction
Connector Engine
Room
J/B No.4 B±G
B±GALT 2
1
4B 14D
FL MAIN 1
J31 J30 B
CBD1
BF1BG1
J33
J34 BE1
BG14
A
A 2
2
3 4
Battery
BS
BTBX S13
Stop Light
Switch1 05±116
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
WIRING DIAGRAM