2003 TOYOTA AVENSIS battery
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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 182 of 2234
031H1±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±13
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE MECHANICAL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Ignition timingw/ 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 gravityat 20C (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 pressureMinimum 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 gravityat 20C (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 pressureMinimum 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.)
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Page 185 of 2234
03±16
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
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 90500
Turn 9036
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 TightenedNmkgf 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
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Page 198 of 2234
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SERVICE SPECIFICATIONS FUEL
03±9
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ftlbf
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 TightenedNmkgf 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
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Page 211 of 2234
030ND±02
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
03±53
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedNmkgf 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 TransaxleBolt 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 cableBolt 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
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Page 212 of 2234
03±54
±
SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ftlbf
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 TransaxleBolt 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
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Page 225 of 2234
031E6±01
03±32
±
SERVICE SPECIFICATIONS STARTING & 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
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