Page 169 of 2234

030L2±04
03±56
±
SERVICE SPECIFICATIONS CLUTCH
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN mkgf cmft lbf
Clutch pedal support x Stopper bolt2525018
Clutch pedal sub±assy x Clutch pedal support3737527
Clutch pedal support x Body1919514
Clutch pedal support x Clutch start switch assy1616012
Clutch master cylinder push rod clevis lock nut121209
Clutch master cylinder x Flexible hose tube1515511
Clutch master cylinder x Body121209
Clutch release cylinder bleeder plug8.48574 in. lbf
Clutch release cylinder x Transaxle housing
1CD±FTV/1AZ±FSE/1AZ±FE engine type
121209
Clutch release cylinder x Transaxle housing 1ZZ±FE/3ZZ±FE engine type1414110
Clutch release cylinder x Flexible hose tube bracket 1ZZ±FE/3ZZ±FE engine type
5.05144 in.lbf
Clutch release cylinder x Clutch line clamp 1AZ±FSE/1AZ±FE engine type121229
Clutch release cylinder x Flexible hose tube1515511
Clutch release cylinder x Clutch accumulator assy 1CD±FTV engine type121209
Clutch accumulator assy x Flexible hose tube 1CD±FTV engine type1515511
Clutch cover assy x Flywheel sub±assy1919514
Release fork support x Transaxle assy 1AZ±FSE/1AZ±FE engine type
1ZZ±FE/3ZZ±FE/1CD±FTV engine type48
37480
37535
27
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Page 170 of 2234
031HJ±01
03±68
±
SERVICE SPECIFICATIONS COMMUNICATION SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
COMMUNICATION SYSTEM
TORQUE SPECIFICATION
Part TightenedN mkgf cmft lbf
HIGH PITCHED HORN ASSY
High pitched horn assy x Body2019915
LOW PITCHED HORN ASSY
Low pitched horn assy x Body2019915
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Page 171 of 2234

031H3±01
03±24
±
SERVICE SPECIFICATIONS COOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Thermostat
Valve opening temperature
Valve lift at 95 C (203F)
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 (68F)
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 (203F)
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 (68F)
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 (203F)
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)
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Page 172 of 2234

±
SERVICE SPECIFICATIONS COOLING
03±25
AVENSIS REPAIR MANUAL (RM1018E)
Cooling fan
Standard amperage at 20
C (68F)
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 (203F)
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 (68F)
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)
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Page 173 of 2234

031H4±01
03±26
±
SERVICE SPECIFICATIONS COOLING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN mkgf cmft lbf
Radiator drain plug131309
Water pump x Cylinder block Bolt A
Bolt B9.0 1192
11 38.0 in.lbf 8
Water inlet x Cylinder block sub±assy1111 28
Radiator x Radiator support upper1919414
1AZ±FE:
Part TightenedNmkgf cmft lbf
Water pump x Cylinder block9.09280 in. lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.lbf
Radiator support upper x body1919414
1AZ±FSE:
Part TightenedNmkgf cmft lbf
Water pump x Cylinder block9.09280 in. lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.lbf
Radiator support upper x body1919414
1CD±FTV:
Part TightenedNmkgf cmft lbf
Drain plug1313310
Water pump x Cylinder block3132023
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 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
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in. lbf
Engine cover No. 1 x Intake manifold8.08271 in.lbf
Timing belt idler Sub±assy No.1 x Cylinder block3535726
Water inlet x Cylinder block8.89078 in.lbf
Radiator reserve tank assy x Radiator assy6.06153 in.lbf
Fan assy w/ motor x Fan shroud assy7.57666 in.lbf
Upper support x Body1919414
Relay box x Radiator assy5.35447 in.lbf
Front wheel1031,05076
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Page 174 of 2234
030KB±05
±
SERVICE SPECIFICATIONS DRIVE SHAFT / PROPELLER SHAFT / AXLE
03±39
AVENSIS REPAIR MANUAL (RM1018E)
DRIVE SHAFT / PROPELLER SHAFT / AXLE
SERVICE DATA
Front axle hub bearing BacklashMaximum: 0.05 mm (0.0020 in.)
Front axle hub sub±assyDeviationMaximum: 0.05 mm (0.0020 in.)
Rear axle hub & bearing assy Backlash
DeviationMaximum: 0.05 mm (0.0020 in.)
Maximum: 0.07 mm (0.0028 in.)
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Page 175 of 2234

030KC±06
03±40
±
SERVICE SPECIFICATIONS DRIVE SHAFT / PROPELLER SHAFT / AXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN mkgf cmft lbf
Front wheel set nut1031,05076
Rear wheel set nut1031,05076
Manual transaxle oil drain plug C50/C250:
E354/E357:39
49400
50029
36
Lower ball joint assy front x Suspension arm sub±assy lower No.18990866
Tie rod end sub±assy x Steering knuckle4950036
Flexible hose and speed sensor front x Shock absorber assy front1919414
Speed sensor front x Steering knuckle8.08271 in. lbf
Front stabilizer link assy x Shock absorber assy front7475555
Front axle hub nut2162,200159
Disc brake dust cover front x Steering knuckle8.38573 in.lbf
Lower ball joint assy front x Steering knuckle1031,05076
Front axle assy x Shock absorber assy front2202,243162
Front disc brake caliper assy x Steering knuckle1021,04075
Automatic transaxle fluid drain plug4950036
Drive shaft bearing case x Bearing bracket6465047
Rear axle hub & bearing assy x Rear axle carrier sub±assy5657141
Rear axle carrier sub±assy x Back plate assy1401,428103
Rear axle carrier sub±assy x Skid control sensor wire5.05144 in.lbf
Rear disk brake caliper assy x Rear axle carrier sub±assy4747534
Rear axle carrier sub±assy x Upper control arm assy7475555
Rear axle carrier sub±assy x Lower control arm assy ball joint side:
member side:60
105612
1,07144
77
Rear axle carrier sub±assy x Rear suspension arm assy ball joint side: member side:105741,071 75577
55
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Page 176 of 2234

031FP±01
03±10
±
SERVICE SPECIFICATIONS EMISSION CONTROL
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Heated oxygen sensor
Resistance Bank 1 sensor 1 1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10 at 20C (68 F)
No continuity
Heated oxygen sensor
Resistance Bank 1 sensor 2 1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10 at 20C (68 F)
No continuity
Vacuum switching valve
Resistance at 20 C (68F)
26 to 30
1AZ±FE:
Vacuum switching valve assy No. 1
Resistance at 20 C (68F)
26 to 30
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16 at 20C (68F)
No continuity
Air fuel ratio sensor
Resistance 1 (HT) ± 2 (+B) 1 (HT) ± 2 (+B)
1 (HT) ± 4 (E1)
1.8 to 3.4 at 20 C (68 F)
5.0 to 7.5 at 500 C (932 F)
No continuity
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20 C (68F)
26 to 30
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16 at 20C (68F)
No continuity
1CD±FTV:
EGR valve assy
Resistance +B1 ± EGR1 +B1 ± EGR2
+B1 ± EGR3
+B1 ± EGR4
19.6 1.4 at 20C (68 F)
19.6 1.4 at 20C (68 F)
19.6 1.4 at 20C (68 F)
19.6 1.4 at 20C (68 F)
Vacuum switching valve assy
Resistance at 20 C (68F)
10 to 14
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