2005 TOYOTA AVENSIS MOTOR

160MG±01
±
COOLING RADIATOR ASSY(1CD±FTV)
16±51
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
5.DISCONNECT RADIATOR HOSE INLET
6.DISCONNECT RADIATOR HOSE OUTLET
7.REMOVE RADIATOR ASSY
(a)Remove the 2 bolts and separate the relay box.
(b)Remove the 2 upper support and radiator assy.
8.REMOVE RADIATOR SUPPORT LOWER
9.REMOVE FAN ASSY W/MOTOR
(a)Remove the 2 bolts and the fan w/motor.
10.INSTALL FAN ASSY W/MOTOR
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
11.INSTALL RADIATOR ASSY
(a)Install the 2 upper support and the radiator assembly to the vehicle. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b)Install the 2 bolts and the relay box.
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
12.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
13.ADD ENGINE COOLANT(See page 16±44)
14.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)

190NQ±01
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow
B00543
± STARTING & CHARGINGCHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
19±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.
4. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.

190NN±01
A81051
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow 19±26
± STARTING & CHARGINGCHARGING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY SPECIFIC GRAVITY
(MAINTENANCE TYPE BATTERY)
(a) Check the specific gravity of each cell.
Standard specific gravity: 1.25 to 1.29 at 20
C (68
F)
HINT:
If the specific gravity is less than specification, charge the bat-
tery.
3. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20
C (68
F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
(Non maintenance type battery)
HINT:
Indicator colorConditionType AType BCondition
GreenBlueGood
DarkWhiteCharging necessary
Clear or light yellowRedReplace
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.

190NT±01
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow
B00543
19±18
± STARTING & CHARGINGCHARGING SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.
4. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.

190NW±01
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow
B00543
± STARTING & CHARGINGCHARGING SYSTEM (1AZ±FE)
19±15
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.
4. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.

SA0028
AB
FrontA B
A: Inside
B: Outside
Z03382
Alignment
TesterGauge
± FRONT SUSPENSIONFRONT WHEEL ALIGNMENT
26±7
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT WHEEL ANGLE
(a) Turn the steering wheel fully and measure the turning
angle.
Wheel turning angle:
(Normal package)
Inside wheel
17'  2 

  

47'  2 

  
Outside wheel: Reference3252'  

315'  

(Rough road package)
Inside wheel
42'  2 
  
09'  2  
  
Outside wheel: Reference3316'  
3138'   
*1: Electric motor power steering models
*2: Oil pressure power steering models
If the right and left inside wheel angles differ from the specified
value, check the right and left rack end lengths.
6. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
(a) Install the camber±caster±kingpin gauge or position the
vehicle on the wheel alignment tester.
(b) Inspect the camber, caster and steering axis inclination.
Camber, caster and steering axis inclination:
(Normal package)
Camber
Right±left error±034'  45' (±0.57  0.75)
45' (0.75) or less
Caster
Right±left error54'  45' (2.90  0.75)
45' (0.75) or less
Steering axis inclination
Right±left error27'  45' (12.45  0.75)
45' (0.75) or less
(Rough road package)
Camber
Right±left error±019'  45' (±0.32  0.75)
45' (0.75) or less
Caster
Right±left error40'  45' (2.67  0.75)
45' (0.75) or less
Steering axis inclination
Right±left error56'  45' (11.93  0.75)
45' (0.75) or less
If the caster and steering axis inclination are not within the spe-
cified values, after the camber has been correctly adjusted, re-
check the suspension parts for damaged and/or worn out parts.

320VW±01
F45949
32±56
± BRAKEBRAKE ACTUATOR ASSY (W/ VSC)
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/ VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

320VY±01
F45949
± BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32±53
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/O VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR