2005 TOYOTA AVENSIS service

031HM±01
± SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
03±63
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Horn button assy x Steering wheel assy8.89078 in.
lbf
Steering wheel assy x Steering column assy5051037
Instrument panel passenger airbag assy x Instrument panel reinforcement2020014
Curtain shield airbag assy x Body3.53631 in.
lbfCurtain shield airbag assy x Body3.5
14
36
143
31 in.lbf
10
Instrument panel airbag assy x Instrument panel reinforcement1818413
Airbag sensor assy center x Body17.517813
Airbag front sensor set bolt7.57666 in.
lbf
Side airbag sensor assy LH x Body17.517813
Airbag sensor rear LH x Body17.517813
Seat position airbag sensor x Front seat8.08271 in.
lbf

031HI±01
03±62
± SERVICE SPECIFICATIONSHEATER AND AIR CONDITIONING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
Tighten2.52522 in.
lbf
Fully tighten3939029
AIR CONDITIONER RADIATOR ASSY
Air conditioning tube assy x Cooler evaporator sub±assy No. 13.53530 in.
lbf
Air conditioner unit assy x Body9.810087 in.
lbf
BLOWER ASSY
Blower assy x Body Bolt:9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1ZZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1AZ±FE)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
W/PULLEY COMPRESSOR ASSY (1CD±FTV)
W/pulley compressor assy x Engine2930021
Cooler refrigerant discharge hose No. 1 x W/pulley compressor assy9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x W/pulley compressor assy RHD:9.810087 in.
lbf
Suction servic valve x W/pulley compressor assy LHD:9.810087 in.
lbf
Cooler refrigerant suction hose No. 1 x Suction servic valve9.810087 in.
lbf
W/RECEIVER CONDENSER ASSY
Cap x W/receiver condenser assy2.92925 in.
lbf
Magnet valve x W/receiver condenser assy3.43530 in.
lbf
Discharge tube x Magnet valve3.43530 in.
lbf
Discharge tube x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy B x W/receiver condenser assy5.45547 in.
lbf
Discharge hose sub±assy x W/receiver condenser assy5.45547 in.
lbf
Liquid tube sub±assy A x W/receiver condenser assy5.45547 in.
lbf
HEAER ASSY
Heater assy x Body7.57666 in.
lbf

031HH±01
± SERVICE SPECIFICATIONSHEATER AND AIR CONDITIONING
03±61
AVENSIS REPAIR MANUAL (RM1018E)
HEATER AND AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume Standard:440
30 g (15.51
1.06 oz.)
Belt deflection New belt:
Used belt:11 ± 13 mm (0.43 ± 0.51 in.)
13.5 ± 16.5 mm (0.53 ± 0.64 in.)

030G7±04
03±60
± SERVICE SPECIFICATIONSPOWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN
mkgf
cmft
lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356
81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.
lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)

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)

031FZ±01
03±58
± SERVICE SPECIFICATIONSSTEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Steering intermediate shaft assy No. 2 x Oil pressure power steering
column assy (LHD steering positoin type)2828621
Steering sliding yoke sub±assy x Oil pressure power steering column assy
(RHD steering positoin type)2828621
Steering intermediate shaft assy No. 2 x Electric power steering column
assy (LHD steering positoin type)3536026
Steering sliding yoke sub±assy x Electric power steering column assy
(RHD steering positoin type)3536026
Steering sliding yoke sub±assy x Steering intermediate shaft assy No. 23536026
Steering column assy set bolt2121415
Steering sliding yoke sub±assy x Steering gear assy
(LHD steering positoin type)3536026
Steering intermediate shaft assy No. 2 x Steering gear assy
(RHD steering positoin type)3536026
Steering wheel set nut5051037
Steering wheel pad set screw (Torx screw)8.89078 in.´lbf
Steering column cover LWR x Steering column assy5.05144 in.´lbf
Instrument panel airbag assy1818413
Power steering ECU assy (Bolt A)88271 in.´lbf
Power steering ECU assy (Bolt B)15.515811

031FX±01
± SERVICE SPECIFICATIONSSTEERING COLUMN
03±57
AVENSIS REPAIR MANUAL (RM1018E)
STEERING COLUMN
SERVICE DATA
STEERING SYSTEM
Steering wheel freeplay Maximum30 mm (1.18 in.)

030L2±04
03±56
± SERVICE SPECIFICATIONSCLUTCH
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