battery TOYOTA AVENSIS 2005 Service Repair Manual

010BA±14
01±42
± INTRODUCTIONTERMS
AVENSIS REPAIR MANUAL (RM1018E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI/INJ)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

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

010B7±13
01±22± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic
procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods
for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning trouble-
shooting of that circuit.
1 Vehicle brought to workshop
2 Customer problem analysis
(a) Ask the customer about the conditions and environment when the problem occurred.
3 Symptom confirmation and DTC (and freeze frame data) check
(a) Check the battery positive voltage.
Voltage: 11 ± 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions, and check for DTCs according to the related chart.
OK Go to step 5
NG
4 DTC chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the DTC chart.
Go to step 6
5 Problem symptoms chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the problem symptoms table.
6 Circuit inspection or parts inspection
(a) Confirm the circuit for the system or the part which should be checked using the problem symptoms
table or the results obtained in step 4.
7 Repair
(a) Repair the affected system or part in accordance with the instructions in step 6.

L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
±
INTRODUCTION REPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE
(1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.

D26613
Example:
D25080
Negative (±)
Terminal
± INTRODUCTIONREPAIR INSTRUCTION
01±15
AVENSIS REPAIR MANUAL (RM1018E)
(8) Oil or water should not be put on the front seat outer belt and the front seat outer belt should be
cleaned with the appropriate detergents.
(i) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved in a collision where the SRS has deployed.
(2) The connectors to the airbag sensor assembly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted to the floor, it could cause an undesired ignition of the supple-
mental restraint system.
(3) Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº
position and the negative (±) terminal cable is disconnected from the battery, even if only loosen-
ing the set bolts of the airbag sensor assembly.
(j) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All connec-
tors in the system are a standard yellow color. If the SRS wire harness becomes disconnected
or the connector becomes broken due to an accident, etc., repair or replace it.
3. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (±) terminal cable beforehand in
order to prevent it from shorting and burning out.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF, and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal.
(3) When the battery terminal cable is removed, the
memories of the clock, radio, DTCs, etc. are erased.
So before removing it, check them and make a note
of their settings.
(4) When the battery negative (±) terminal cable is dis-
connected, memories of various systems are
erased. Therefore, refer to the PRE±CHECK for
each system to make sure whether or not the sys-
tem needs to be initialized after the battery negative

031H3±01
03±24
± SERVICE SPECIFICATIONSCOOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
86 to 90
C (187 to 198
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.6 psi)
Cooling fan
Standard amperage at 20
C (68
F)
8 to 12 A
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1AZ±FE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
80 to 84
C (176 to 183
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
93 ± 122 kPa (0.95 ± 1.25 kgf/cm2, 13.4 ± 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.2 psi)
Cooling fan
Standard amperage at 20
C (68
F)
Standard amperage (No.2 (With Air Conditioner)) at 20
C (68
F)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1AZ±FSE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
86 to 90
C (187 to 198
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)

± SERVICE SPECIFICATIONSCOOLING
03±25
AVENSIS REPAIR MANUAL (RM1018E) Cooling fan
Standard amperage at 20
C (68
F)
Standard amperage (No.2 (With Air Conditioner)) at 20
C (68
F)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1CD±FTV:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
80 ± 84
C (176 ± 183
F)
8.5 mm (0.33 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
93 ± 122 kPa (0.95 ± 1.25 kgf/cm2, 13.4 ± 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.4 psi)
Cooling fan
Standard amperage at 20
C (68
F)
13.2 A
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2
Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)

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

031H1±01
± SERVICE SPECIFICATIONSENGINE MECHANICAL
03±13
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE MECHANICAL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Ignition timing w/ Terminal TC and CG of DLC3 connected
W/ Terminal TC and CG of DLC3 disconnected8 to 12
BTDC
10 to 18
BTDC (1ZZ±FE)
3.5 to 11.5
BTDC (3ZZ±FE)
Idle speed600 to 700 rpm
Compression
Compression pressure
Minimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf
cm2, 189 psi)
1,000 kPa (10.2 kgf
cm2, 145 psi)
100 kPa (1.0 kgf
cm2, 14 psi)
Cylinder head set bolt Length Standard
Maximum146.8 to 148.2 mm (5.780 to 5.835 in.)
148.5 mm (5.846 in.)
Valve clearance (Cold)
No. 1 Cylinder TDC/Compression Intake
Exhaust
No. 4 Cylinder TDC/Compression Intake
Exhaust
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
1AZ±FE:
Battery specific gravity at 20
C (68
F)1.25 to 1.29
Ignition timing w/ Terminals TC and CG of DLC3 connected
w/ Terminals TC and CG of DLC3 disconnected8 to 12
BTDC
5 to 15
BTDC
Idle speed650 to 750 rpm
Compression
Compression pressure
Minimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf/cm2, 189 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 14 psi)
Cylinder head set bolt
Bolt length Standard
Maximum
161.3 to 162.3 mm (6.350 to 6.390 in.)
164.2 mm (6.465 in.)
Valve clearance
Intake (Cold)
Exhaust
0.19 to 0.29 mm (0.0075 to 0.0114 in.)
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
1AZ±FSE:
Battery specific gravity at 20
C (68
F)1.25 to 1.29
Ignition timing w/ Terminals TC and CG of DLC3 connected
w/ Terminals TC and CG of DLC3 disconnected8 to 12
BTDC
5 to 23
BTDC
Idle speed625 to 725 rpm
Compression
Compression pressure
Minimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf/cm2, 189 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 14 psi)
Cylinder head set bolt
Bolt length Standard
Maximum
161.3 to 162.3 mm (6.350 to 6.390 in.)
164.2 mm (6.465 in.)
Valve clearance
Intake (Cold)
Exhaust
0.19 to 0.29 mm (0.0075 to 0.0114 in.)
0.30 to 0.40 mm (0.0118 to 0.0157 in.)

± 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