length TOYOTA AVENSIS 2005 Service Repair Manual

± 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

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.

± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
02±53
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09042±00010Torx Socket T30HORN BUTTON ASSY
SPIRAL CABLE SUB±ASSY
09070±20010Moulding RemoverAIR BAG SENSOR ASSY CENTER
Equipment
Torque wrench
Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
Plastic bagAirbag disposal

031E2±02
03±22
± SERVICE SPECIFICATIONSEXHAUST
AVENSIS REPAIR MANUAL (RM1018E)
EXHAUST
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Compression spring
Free length Minimum Front x Manifold
Front x Tail
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
1AZ±FE/1AZ±FSE:
Compression spring
Free length Minimum Front x Manifold
Center x Tail
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
1CD±FTV:
Compression spring
Minimum length Exhaust pipe assy front x Exhaust manifold
41.5mm (1.634 in)
Compression spring
Minimum length Exhaust pipe assy front x Tail pipe assy
38.5mm (1.515 in)

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.)

031E0±01
± SERVICE SPECIFICATIONSFUEL
03±7
AVENSIS REPAIR MANUAL (RM1018E)
FUEL
SERVICE DATA
GASOLINE:
Compression spring
Free length Minimum Front x Manifold (1ZZ±FE/3ZZ±FE)
Front x Tail (1ZZ±FE/3ZZ±FE)
Center x Tail (1AZ±FE/1AZ±FSE)
41.5 mm (1.634 in.)
38.5 mm (1.516 in.)
38.5 mm (1.516 in.)

0313B±05
03±34
± SERVICE SPECIFICATIONSFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1
± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference0
06'
12' (0.1

0.2
), 1
2 mm (0.04
0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

17'  2

 

32
52' 


42'  2

 

33
16' 

Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

47'  2
 
 

31
15' 


09'  2


 

31
38' 


Camber
Normal package
Rough road package
Right±left error
±0
34'  45' (±0.57
 0.75
)
±0
19'  45' (±0.32
 0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error

54'  45' (2.90
 0.75
)

40'  45' (2.67
 0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27'  45' (12.45
 0.75
)
11
56'  45' (11.93
 0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center

030G6±04
± SERVICE SPECIFICATIONSPOWER STEERING
03±59
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING
SERVICE DATA
POWER STEERING FLUID
Fluid level rise Maximum5 mm (0.20 in.)
Fluid pressure at idle speed with valve closed AZ Series:
1CD±FTV:8,300 to 9,000 kPa (85 to 92 kgf/cm2, 1,204 to 1,305 psi)
8,800 to 9,500 kPa (90 to 97 kgf/cm2, 1,276 to 1,378 psi)
STEERING WHEEL
Steering effort at idle speed (Reference)5.5 N´m (56 kgf´cm, 49 in.´lbf)
VANE PUMP ASSY
Vane pump rotating torque0.27 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
Vane pump shaft and vane pump housing oil clearance Maximum0.07 mm (0.0028 in.)
Vane plate thickness Minimum1.405 to 1.411 mm (0.05531 to 0.05555 in.)
Clearance between the rotor groove and plate Maximum0.03 mm (0.0012 in.)
Spring free length Minimum36.9 mm (1.453 in.)
STEERING GEAR ASSY
Total preload (Tie rod rotating torque) (Turning)0.29 to 1.96 N´m (3 to 20 kgf´cm, 2.57 to 17.35 in.´lbf)
Total preload (Control valve rotating torque) (Turning)0.6 to 1.1 N´m (6 to 11 kgf´cm, 5.3 to 9.7 in.´lbf)
RACK & PINION POWER STEERING GEAR ASSY
Total preload (Tie rod rotating torque) (Turning)0.49 to 3.43 N´m (5 to 35 kgf´cm, 4.34 to 30.38 in.´lbf)

A79111
OCV Signal Waveform1 msec./Division 5 V/
Division
GND
(A)(A) (A)
E13
OC1 +OC1±
A54386
Wire Harness Side
C2
Camshaft Timing Oil Control Valve
Connector
A65743ECM Connector
E13
OC1+OC1±
±
DIAGNOSTICS SFI SYSTEM(1AZ±FE)
05±171
AVENSIS REPAIR MANUAL (RM1018E)
3INSPECT ECM(OCV SIGNAL)
(a)Inspection using the oscilloscope.
(b)During idling, check the waveform between the terminals
of the E13 ECM connector.
Standard:
Symbols (Terminal No.)Specified condition
OC1+ (E13±15) ± OC1± (E13±14)Correct waveform is as shown
HINT:
The waveform frequency (A) is lengthened as the engine speed
becomes higher.
NGCHECK AND REPLACE ECM (See page 01±32)
OK
4 CHECK HARNESS AND CONNECTOR(ECM ± OCV)
(a) Disconnect the camshaft timing oil control valve connec- tor.
(b) Disconnect the E13 ECM connector.
(c) Check for continuity between the wire harness side con- nectors.
Standard (Check for open):
Symbols (Terminal No.)Specified condition
Oil control valve (C2±1) ± OC1+ (E13±15)ContinuityOil control valve (C2±2) ± OC1± (E13±14)Continuity
Standard (Check for short):
Symbols (Terminal No.)Specified condition
Oil control valve (C2±1) or OC1+ (E13±15) ± Body groundNo continuityOil control valve (C2±2) or OC1± (E13±14) ± Body groundNo continuity
NG REPAIR OR REPLACE HARNESS OR CONNECTOR
OK
CHECK FOR INTERMITTENT PROBLEMS

A76968
C2
(±) (+)
Camshaft Timing Oil Control Valve
A79111
OCV Signal Waveform
1 msec./Division5 V/
Division
GND
(A) (A)
(A)
E13
OC1 + OC1±
05±172
± DIAGNOSTICSSFI SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
When not using hand±held tester:
1 CHECK OPERATION OF OCV
(a) Disconnect the camshaft timing oil control valve connec-
tor.
(b) Apply battery positive voltage between the terminals of
the camshaft timing oil control valve.
(c) Check the engine speed.
Standard:
Engine speed is rough idle or engine is stalled.
NG REPLACE CAMSHAFT TIMING OIL CONTROL
VALVE ASSY
OK
2 INSPECT ECM(OCV SIGNAL)
(a) Inspection using the oscilloscope.
(b) During idling, check the waveform between the terminals
of the E13 ECM connector.
Standard:
Symbols (Terminal No.)Specified condition
OC1+ (E13±15) ± OC1± (E13±14)Correct waveform is as shown
HINT:
The waveform frequency (A) is lengthened as the engine speed
becomes higher.
NG CHECK AND REPLACE ECM
(See page )
OK