starter TOYOTA AVENSIS 2005 Service Repair Manual

022L3±01
± PREPARATIONVEHICLE CONTROL SYSTEM
02±63
AVENSIS REPAIR MANUAL (RM1018E)
VEHICLE CONTROL SYSTEM
PREPARATION
Recomended Tools
09082±00040TOYOTA Electrical TesterIGNITION OR STARTER SWITCH
ASSY
09082±00050TOYOTA Electrical Tester SetIGNITION OR STARTER SWITCH
ASSY

030AA±10
03±50
± SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
U341E
Part TightenedN
mkgf
cmft
lbf
Park/neutral position switch x Transaxle Bolt
Nut5.4
6.955
7048 in.
lbf
61 in.
lbf
Control shaft lever x Park/neutral position switch131309
Battery carrier x Body1313210
Engine hanger x Engine3838728
Drain plug x Oil pan4950036
Transaxle x Engine Bolt A:
Bolt B:
Bolt C:64
46
23650
470
23547
34
17
Torque converter clutch x Drive plate2828520
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket FR x Transaxle6465347
Center member x Body Bolt A:4545933
Center member x Suspension member Bolt B:
BoltC:96
52979
53071
38
Engine mounting insulator RR x Engine mounting bracket RR8788764
Engine mounting insulator RR x Suspension member5253038
Engine mounting insulator FR x Engine mounting bracket FR5253038
Engine mounting bracket LH x Transaxle6465347
Engine mounting insulator LH x Body Bolt A:
Nut B:52
80530
81538
59
Starter x Transaxle3737727
Starter wire x Starter9.810087 in.
lbf
Froor panel brace x Body3030222
Oil filler tube x Transaxle Bolt A:121229
Oil cooler tube clamp x Oil filler tube Bolt B:5.55649 in.
lbf
Oil cooler outlet tube x Transaxle3535725
Oil cooler inlet tube x Transaxle3535725
Wire harness clamp bracket x Transaxle121229
Wire harness x Transaxle Bolt A:
Bolt B:5
2651
26544 in.
lbf
19
Control cable bracket x Transaxle121229
Control cable support x Transaxle121229
Air cleaner assy x Body7.07162 in.
lbf
Cylinder head cover No. 2 x Engine7.07162 in.
lbf
Speed sensor x Transaxle5.45548 in.
lbf
Transmission wire x Transaxle5.45548
Solenoid valve x Valve body Bolt A:
Bolt B:11
1111 0
11 08
8
Valve body x Transaxle1111 08
ATF temperature sensor x Valve body1111 08
Oil strainer x Valve body1111 08
Oil pan x Transaxle7.88069 in.
lbf
Floor shift assembly x Body121229
Control cable x Control shaft lever121229

± SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03±51
AVENSIS REPAIR MANUAL (RM1018E) U241E
Part TightenedN
mkgf
cmft
lbf
Park/neutral position switch x Transaxle Bolt
Nut5.4
6.955
7048 in.
lbf
61 in.
lbf
Control shaft lever x Park/neutral position switch131309
Battery carrier x Body1313210
Engine hanger x Engine3838728
Drain plug x Oil pan4950036
Transaxle x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Torque converter clutch x Drive plate4142030
Engine mounting bracket RR x Transaxle6465247
Engine mounting bracket FR x Transaxle6465247
Center member x Body4545933
Center member x Suspension member Bolt B:
Boltc:96
52979
53071
38
Engine mounting insulator RR x Engine mounting bracket RR8788764
Engine mounting insulator RR x Suspension member5253038
Engine mounting insulator FR x Engine mounting bracket FR5253038
Engine mounting bracket LH x Transaxle6465347
Engine mounting insulator LH x Body Bolt A:
Nut B:52
80530
81638
59
Starter x Transaxle3737727
Starter wire x Starter9.810087 in.
lbf
Oil filler tube x Transaxle5.55649 in.
lbf
Oil cooler tube clamp x Oil filler tube5.45547 in.
lbf
Oil cooler outlet tube x Transaxle3434725
Oil cooler inlet tube x Transaxle3434725
Wire harness clamp bracket x Transaxle1313210
Wire harness x Transaxle Bolt A:
Bolt B:5.0
8.451
8644 in.
lbf
74 in.
lbf
Control cable bracket x Transaxle121228
Control cable clamp x Transaxle121229
Air cleaner assy x Body5.05049 in.
lbf
Cylinder head cover sub±assy No. 1 x Engine9.09280 in.
lbf
Transmission wire x Transaxle5.45548 in.
lbf
Solenoid valve x Valve body Bolt A:
Bolt B:6.6
1167
11 058 in.
lbf
8
Valve body x Transaxle1111 08
Manual detent spring x Valve body1111 08
Oil strainer x Valve body1111 08
Oil pan x Transaxle7.88069 in.
lbf
Floor shift assy x Body121229
Control cable x Control shaft lever121229
Control cable x Body Bolt
Nut5.0
5.050
5043 in.
lbf
43 in.
lbf
Speed sensor x Transaxle121229
Drive shaft bearing cace x Bearing bracket6465047

031E7±03
± SERVICE SPECIFICATIONSSTARTING & CHARGING
03±33
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Starter assy x Transaxle housing3737828
Starter wire x Starter assy9.81007
Generator assy x Transverse engine engine mounting bracket2525518
Generator assy x Cylinder block sub±assy5455140
Generator wire x Generator assy9.81007
Lead wire of field coil x Terminal C5.96052 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Wire harness clamp bracket x Starter assy8.48674 in.
lbf
Starter assy x Cylinder block sub±assy3738028
Starter wire x Starter assy9.81007
Battery carrier x Body131319
Battery clamp sub±assy x Body5.05144 in.
lbf
Battery clamp sub±assy x Battery clamp bolt3.63631 in.
lbf
Terminal x Battery5.45548 in.
lbf
Wire harness clamp bracket x Generator assy8.48674 in.
lbf
Generator assy x Cylinder block sub±assy Bolt A
Bolt B52
21530
21438
16
Generator wire x Generator assy9.81007
Lead wire of field coil x Terminal C5.96052 in.
lbf
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Starter x Transaxle Bolt
Terminal 3037
9.8377
10027
7.2
Generator assy x Engine M8
M10
Alternator wire
Wire harness31
47
9.8
5.0320
475
100
5123
34
7
44 in.
lbf
Glow plug assy x Cylinder head Glow plug
Nut12.3
2.2125
229
19 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
Front wheel RH1031,05076

031E6±01
03±32
± SERVICE SPECIFICATIONSSTARTING & CHARGING
AVENSIS REPAIR MANUAL (RM1018E)
STARTING & CHARGING
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Starter assy
Rated voltage and output power
Specified current
12 V 1.3 kW
85 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Voltage at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage12.9 to 14.9 V
10 A or less
1AZ±FE:
Starter assy
Rated voltage and output power
Specified current
12 V 1.3 kW
85 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Voltage at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage12.9 to 14.9 V
10 A or less
1AZ±FSE:
Starter (1.3 kW type)
Rated voltage and output power
No±load characteristics Current
12 V 1.3 kW
85 A or less at 11.5 V
Starter (1.6 kW type)
Rated voltage and output power
No±load characteristics Current
12 V 1.6 kW
75 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Voltage at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage12.9 to 14.9 V
10 A or less
1CD±FTV:
Starter assy
Rated voltage and output power
Specified current
12 V 2.0 kW
190 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Except maintenance±free battery Standard specific gravity
Voltage at 20
C (68
F)
1.25 to 1.29 at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage13.2 to 14.8 V
10 A or less
Glow plugs
Resistance at 20
C (68
F)
Approx. 0.72

Glow plug relay
Specified condition 1 ± 2
3 ± 4
No continuity
Continuity

030ND±02
± SERVICE SPECIFICATIONSMANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
Floor shift transmission control cable assy x Body5.05144 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
FLOOR SHIFT SHIFT LEVER ASSY
Floor shift shift lever assy x Body121229
MANUAL TRANSAXLE ASSY (1ZZ±FE/ 3ZZ±FE)
Filler and drain plugs3940029
Engine hanger set bolt3838728
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
47
23650
480
23047
35
17
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Starter assy x Manual transaxle assy3738027
Starter wire set nut131309
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:
Bolt C:25
14
5.0250
141
2119
10
44 in.
lbf
Manual transaxle assy x Wire harness clmap Bolt A:
Bolt B:26
19260
19519
14
Manual transaxle assy x Ground cable Bolt A:
Bolt B:26
40260
41019
30
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head cover No.2 x Engine7.07162 in.
lbf
Hood set bolt1313310
MANUAL TRANSAXLE ASSY (1AZ±FE/ 1AZ±FSE)
Filler and drain plugs4950036
Engine hanger x Engine3838728
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:64
46
44650
470
44947
34
32
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Manual transaxle assy x Ground cable Bolt A:
Bolt C:26
40260
41019
30
Manual transaxle assy x Wire harness clamp8.48574 in.
lbf
Clutch release cylinder assy x Transaxle Bolt A:
Bolt B:9.0
1292
12080 in.
lbf
9

03±54
± SERVICE SPECIFICATIONSMANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Battery carrier x Body131319
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Engine cover sub±assy No.1 x Engine9.09280 in.
lbf
Hood set bolt1313210
MANUAL TRANSAXLE ASSY (1CD±FTV)
Filler and drain plugs4950036
Engine hanger x Engine3737727
Transmission case protector x Transaxle1818413
Engine mounting bracket RR x Transaxle6465347
Engine mounting bracket RR x Engine mounting insulator RR8788764
Engine mounting bracket FR x Transaxle6465347
Engine mounting bracket FR x Engine mounting insulator FR5253038
Manual transaxle assy x Engine Bolt A:
Bolt B:
Bolt C:
Bolt D:
Bolt E:64
46
40
20
8.0653
469
408
200
8247
34
30
14
71 in.
lbf
Transverse engine engine mounting bracket LH x Transaxle6465347
Engine mounting bracket LH x Engine mounting insulator LH Bolt A:
Nut B:52
80530
81638
59
Accumulator to flexible hose tube x Transaxle Bolt A:
Bolt B:
Bolt C:12
5.0
9.0120
51
929
44 in.
lbf
80 in.
lbf
Manual transaxle assy x Ground cable131319
Air tube No.2 x Transaxle2525518
Starter assy x Transaxle3738027
Starter wire set nut131309
Radiator reserve tank assy x Body6.06153 in.
lbf
Air tube No.1 x Engine2525518
Battery clamp sub±assy x Body Bolt:
Nut:5.0
3.551
3644 in.
lbf
31 in.
lbf
Air cleaner assy x Body7.07162 in.
lbf
Engine cover No.1 x Engine8.08271 in.
lbf
Hood set bolt1313310

0505L±04
05±22
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can\
not be confirmed in the basic inspection, proceed to this problem symptoms \
tables and troubleshoot accord-
ing to the numbered order given below.
SymptomSuspect AreaSee page
Engine does not crank (Does not start)1. Starter and starter relay
2. Neutral start switch circuit*19±1

No initial combustion (Does not start)
1. ECM power source circuit
2. Ignition coil (w/ Igniter) circuit
3. Fuel pump control circuit
4. Fuel system05±124
05±103
05±131
11±1
No complete combustion (Does not start)
1. Fuel pump control circuit
2. Ignition coil (w/ Igniter) circuit
3. Fuel system05±131
05±103
11±1
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Ignition coil (w/ Igniter)
5. Spark plug
6. Compression
7. Fuel system05±135
05±100
05±131
05±10318±3
14±111±1
Cold engine (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Fuel system
5. Ignition coil (w/ Igniter)
6. Spark plug05±135
05±100
05±131 11±1
05±103 18±3
Hot engine (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Fuel system
5. Ignition coil (w/ Igniter)
6. Spark plug05±135
05±100
05±131 11±1
05±103 18±3
Incorrect first idle (Poor idling)1. ISC valve circuit05±100
High engine idle speed (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Neutral start switch circuit*05±100
05±124

Low engine idle speed (Poor idling)
1. ISC valve circuit
2. Neutral start switch circuit*
3. Fuel pump control circuit
4. Fuel system05±100

05±131 11±1
Rough idling (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Fuel pump control circuit05±100
05±124
05±131
Hunting (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Fuel pump control circuit05±100
05±124
05±131
Hesitation/Poor acceleration (Poor drivability)
1. Fuel system
2. Fuel pump control circuit
3. Ignition coil (w/ Igniter) circuit11±1
05±131
05±103
Muffler explosion, after fire (Poor drivability)
1. Ignition coil (w/ Igniter) circuit
2. Spark plug
3. Fuel system05±103 18±3
11±1
Surging (Poor drivability)
1. Fuel pump control circuit
2. Spark plug
3. Fuel system05±131 18±3
11±1

05C6Q±01
05±168
±
DIAGNOSTICS SFI SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee page
Engine does not crank (Does not start)1. Starter
2. Starter relay19±8
19±8
No initial combustion (Does not start)
1. ECM power source circuit
2. Fuel pump control circuit
3. ECM05±257
05±264 01±32
No complete combustion (Does not start)1. Fuel pump control circuit05±264
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. Fuel pump control circuit
3. Compression05±278
05±264
14±101
Cold engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuit05±278
05±264
Hot engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuit05±278
05±264
High engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit

05±257
Low engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuit

05±264
Rough idling (Poor idling)1. Compression
2. Fuel pump control circuit14±101
05±264
Hunting (Poor idling)1. ECM power source circuit
2. Fuel pump control circuit05±257
05±264
Hesitation/Poor acceleration (Poor driveability)1. Fuel pump control circuit
2. A/T faulty05±264
05±879
Surging (Poor driveability)1. Fuel pump control circuit05±264
Engine stalls soon after starting1. Fuel pump control circuit05±264
Engine stalls during A/C operation1. A/C signal circuit (Compressor circuit)
2. ECM

01±32
Unable to refuel/Difficult to refuel1. ORVR system

± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±135
AVENSIS REPAIR MANUAL (RM1018E)
STARTER SIGNAL CIRCUIT
CIRCUIT DESCRIPTION
When the engine is cranked, the intake air flow becomes slow, so fuel vaporization is poor. A rich mixture
is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery
voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection
volume for the starting injection control and after±start injection control.
05C6I±01