air suspension TOYOTA AVENSIS 2005 Service Repair Manual

010B9±11
± INTRODUCTIONTERMS
01±37
AVENSIS REPAIR MANUAL (RM1018E)
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
CANController Area Network
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

± INTRODUCTIONTERMS
01±39
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
H±FUSEHigh Current Fuse
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

01±40
± INTRODUCTIONTERMS
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
OEMOriginal Equipment Manufacturing
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

022L8±01
02±26
± PREPARATIONREAR SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
REAR SUSPENSION
PREPARATION
SST
09610±20012Pitman Arm PullerREAR SUSPENSION ARM ASSY
NO.1 LH
LOWER CONTROL ARM ASSY LH
09628±62011Boll Joint PullerREAR SUSPENSION ARM ASSY
NO.1 LH
09632±36010Steering Vane Pump Bearing
ReplacerREAR SUSPENSION ARM ASSY
NO.1 LH
09727±30021Coil Spring CompressorREAR SHOCK ABSORBER WITH
COIL SPRING
(09727±00010)Bolt SetREAR SHOCK ABSORBER WITH
COIL SPRING
(09727±00021)Arm SetREAR SHOCK ABSORBER WITH
COIL SPRING
(09727±00031)CompressorREAR SHOCK ABSORBER WITH
COIL SPRING
09950±40011Puller B SetREAR SUSPENSION ARM ASSY
NO.1 LH
(09951±04010)Hanger 150REAR SUSPENSION ARM ASSY
NO.1 LH
(09952±04010)Slide ArmREAR SUSPENSION ARM ASSY
NO.1 LH
(09953±04030)Center Bolt 200REAR SUSPENSION ARM ASSY
NO.1 LH
(09954±04020)Arm 100REAR SUSPENSION ARM ASSY
NO.1 LH

± PREPARATIONREAR SUSPENSION
02±27
AVENSIS REPAIR MANUAL (RM1018E)
(09955±04051)Claw No.5REAR SUSPENSION ARM ASSY
NO.1 LH
(09957±04010)AttachmentREAR SUSPENSION ARM ASSY
NO.1 LH
(09958±04011)HolderREAR SUSPENSION ARM ASSY
NO.1 LH
Recomended Tools
09040±00011Hexagon Wrench SetREAR SHOCK ABSORBER WITH
COIL SPRING
REAR SUSPENSION ARM ASSY
NO.1 LH
STABILIZER BAR REAR
(09043±20050)Socket Hexagon Wrench 5REAR SHOCK ABSORBER WITH
COIL SPRING
REAR SUSPENSION ARM ASSY
NO.1 LH
STABILIZER BAR REAR
(09043±20060)Socket Hexagon Wrench 6REAR SHOCK ABSORBER WITH
COIL SPRING
Equipment
Torque wrench
Dial indicator with magnetic base
Wheel balancer
Tire pressure gauge
Alignment tester
Toe±in gauge
Camber±caster±kingpin gauge
Drill

022KF±01
± PREPARATIONFRONT SUSPENSION
02±25
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
PREPARATION
SST
09628±62011Boll Joint PullerLOWER BALL JOINT ASSY FRONT
LH
STABILIZER BAR FRONT
FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH(ATM)
09727±30021Coil Spring CompressorFRONT SHOCK ABSORBER WITH
COIL SPRING
09729±22031Front Spring Upper Seat HolderFRONT SHOCK ABSORBER WITH
COIL SPRING
09930±00010Drive Shaft Nut ChiselLOWER BALL JOINT ASSY FRONT
LH
Recomended Tools
09011±12301Socket Wrench 30 mmLOWER BALL JOINT ASSY FRONT
LH
09040±00011Hexagon Wrench SetFRONT SHOCK ABSORBER WITH
COIL SPRING
STABILIZER BAR FRONT
FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH(ATM)
FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH(MTM)
(09043±20060)Socket Hexagon Wrench 6FRONT SHOCK ABSORBER WITH
COIL SPRING
STABILIZER BAR FRONT
FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH(ATM)
FRONT SUSPENSION ARM
SUB±ASSY LOWER NO.1 LH(MTM)
Equipment
Torque wrench
Dial indicator with magnetic base
Tire pressure gauge
Alignment tester
Toe±in gauge
Angle gauge
Camber±caster±kingpin gauge
Engine Sling Device
Drill

± PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02±37
AVENSIS REPAIR MANUAL (RM1018E)
(09316±00011)Replacer PipeFRONT DIFFERENTIAL OIL
SEAL(U241E)
09350±32014TOYOTA Automatic Transmission
Tool SetTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09351±32010)One±way Clutch Test ToolTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09351±32020)Stator StopperTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09520±01010Drive Shaft Remover AttachmentAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09520±24010Differential Side Gear Shaft
PullerAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
(09520±32040)Shocker SetAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09554±14010Differential Oil Seal ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)
09628±62011Boll Joint PullerAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09649±17010Steering Knuckle ToolFRONT DIFFERENTIAL OIL
SEAL(U241E)
09726±27012Front Suspension Arm Bushing
Remover & ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)

031H2±01
± SERVICE SPECIFICATIONSENGINE MECHANICAL
03±15
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Camshaft bearing cap No. 3 x Cylinder head sub±assy1313310
Camshaft bearing cap No. 1 x Cylinder head sub±assy2323517
Camshaft timing gear or sprocket x Camshaft No. 25455140
Chain tensioner assy No. 1 x Timing chain or belt cover sub±assy9.09280 in.
lbf
V±ribbed belt tensioner assy x Cylinder block sub±assy6970451
V±ribbed belt tensioner assy x Cylinder head sub±assy2929621
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting bracket5253038
Cylinder head cover sub±assy x Cylinder head sub±assy A
B11
9.011 2
928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Ignition coil assy x Cylinder head cover sub±assy9.09280 in.
lbf
Engine wire x Cylinder head cover sub±assy9.09280 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Engine hanger x Cylinder head sub±assy3838728
Radio setting condenser x Cylinder head sub±assy101027
Engine coolant temperature sensor x Cylinder head sub±assy2020415
Exhaust manifold x Cylinder head sub±assy3737727
Exhaust manifold heat insulator No. 1 x Exhaust manifold Bolt
Nut18
12184
12213
9
Manifold stay No. 2 x Exhaust manifold4950036
Manifold stay No. 2 x Cylinder block sub±assy4950036
Manifold stay x Exhaust manifold A4950036
Manifold stay x Cylinder block sub±assy B3737727
Transverse engine engine mounting bracket x Timing chain or belt cover
sub±assy4747935
V±ribbed idler assy No.1 x Cylinder block sub±assy39.240029
Knock sensor x Cylinder block sub±assy2020415
Crankshaft position sensor x Timing chain or belt cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Water inlet x Cylinder block sub±assy1111 28
Water by±pass pipe No. 1 x Cylinder block sub±assy9.09280 in.
lbf
Water by±pass pipe No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Oil level gage guide x Water by±pass pipe No. 11313310
Intake manifold x Cylinder head sub±assy3030622
Flywheel sub±assy x Crankshaft 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Drive plate & ring gear sub±assy x Crankshaft8889765
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front5253038
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Transverse engine engine mounting bracket LH x Transverse engine engine
mounting insulator LH8081659
Transverse engine engine mounting bracket RH x Transverse engine engine
mounting insulator RH5253038
Front suspension crossmember sub±assy x Body A
B45
133459
1,35633
98
Front suspension member brace x Body Bolt A
Bolt B133
801,356
81698
59

03±16
± SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Floor panel brace front x Body3030622
Battery carrier x Body12.81319
Battery x Body5.05144 in.
lbf
Air cleaner case x Body5.05144 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket LH5.05144 in.
lbf
Radiator support upper x Body1919414
Front wheel RH & LH x Front axle hub sub±assy RH & LH1031,05076
Camshaft timing gear assy x Camshaft5455140
Chain tensioner slipper x Cylinder block sub±assy1919414
Timing chain or belt cover sub±assy x Cylinder head sub±assy1313310
Timing chain or belt cover sub±assy x Cylinder block sub±assy M6
M813
19133
19410
14
Crankshaft pulley x Crankshaft1381,407102
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block sub±assy9.09280 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Intake manifold x Cylinder head3030622
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133
801,356
81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356
81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038

±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body
w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815