2005 TOYOTA AVENSIS MOTOR

031H4±01
03±26
± SERVICE SPECIFICATIONSCOOLING
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 TightenedN
mkgf
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 TightenedN
mkgf
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 TightenedN
mkgf
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

0313B±05
03±34
± SERVICE SPECIFICATIONSFRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1
± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference0
06'
12' (0.1

0.2
), 1
2 mm (0.04
0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

17'  2

 

32
52' 


42'  2

 

33
16' 

Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel
Outside wheel: Reference

47'  2
 
 

31
15' 


09'  2


 

31
38' 


Camber
Normal package
Rough road package
Right±left error
±0
34'  45' (±0.57
 0.75
)
±0
19'  45' (±0.32
 0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error

54'  45' (2.90
 0.75
)

40'  45' (2.67
 0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27'  45' (12.45
 0.75
)
11
56'  45' (11.93
 0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center

031HN±01
± SERVICE SPECIFICATIONSSEAT
03±71
AVENSIS REPAIR MANUAL (RM1018E)
SEAT
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FRONT SEAT
Seat Inner belt assy x Seat adjuster assy4242831
Seatback cover bracket x Seat adjuster assy (w/ Side airbag)6.06153 in.
lbf
Seat assy x Body3737527
Seat position airbag sensor x Seat adjuster assy8.08271 in.
lbf
Power seat motor assy (Reclining) x Seat adjuster assy4.54640 in.
lbf
Power seat motor assy (Slide) x Seat adjuster assy Bolt
Nut4.0
3.541
3635 in.
lbf
31 in.
lbf
Power seat motor assy (lifter) x Seat adjuster assy Bolt
Nut2.5
2525
25522 in.
lbf
18
Power seat motor assy (Front vertical) x Seat adjuster assy Bolt
Nut2.5
2525
25522 in.
lbf
18
Front seatback spring assy x Front seat adjuster2525518
REAR SEAT
Armrest assy x Seatback assy8.08271 in.
lbf
Seat belt assy outer center x Seatback frame4242831
Seat belt assy outer center x Body4242831
Seatback lock assy x Seatback frame3030622
Seatback hinge x Seatback frame1818513
Seatback hinge x Body1818513
Seatback hinge center x Body1818513
Seatback hinge center x Seatback frame1818513
Side seatback assy x Body1818513
Bench type seatback assy x Body1818513
Seat cushion frame x Body1818513

031HA±01
03±66
± SERVICE SPECIFICATIONSWIPER & WASHER
AVENSIS REPAIR MANUAL (RM1018E)
WIPER & WASHER
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wiper motor x Wiper link7.57666 in.
lbf
Wiper link x Body5.55649 in.
lbf
Wiper arm x Wiper link2121015
Rear wiper motor x Body5.55649 in.
lbf
Rear wiper motor x Rear wiper arm5.55649 in.
lbf

±
DIAGNOSTICS SFI SYSTEM (1AZ±FSE)
05±315
AVENSIS REPAIR MANUAL (RM1018E)


\f  
*
1
CHK ENG
 
 \b
P0746 *3,4
(05±954)
Pressure Control Solenoid ºAº
Performance (Shift Solenoid
Valve SL1)

Electronic controlled automatic transmission (ECT)
P0748 *4
(05±956)
Pressure Control Solenoid ºAº
Electrical (Shift Solenoid Valve
SL1)

Electronic controlled automatic transmission (ECT)
P0766 *3,4
(05±962)
Shift Solenoid ºDº Performance
(Shift Solenoid Valve S4)
Electronic controlled automatic transmission (ECT)
P0776 *3,4
(05±963)
Pressure Control Solenoid ºBº
Performance (Shift Solenoid
Valve SL2)

Electronic controlled automatic transmission (ECT)
P0778 *4
(05±956)
Pressure Control Solenoid ºBº
Electrical (Shift Solenoid Valve
SL2)

Electronic controlled automatic transmission (ECT)
P0793 *4
(05±965)
Intermediate Shaft Speed Sen-
sor ºAº Circuit No Signal
Electronic controlled automatic transmission (ECT)
P0982 *4
(05±956)Shift Solenoid ºDº Control Low
Electronic controlled automatic transmission (ECT)
P0983 *4
(05±956)Shift Solenoid ºDº Control High
Electronic controlled automatic transmission (ECT)
P1235
(05±477)High Pressure Fuel Pump Circuit

Open or short in fuel pump (high pressure)

Fuel pump (high pressure)

ECM

P2008
(05±480)Intake Manifold Runner Control
Circuit/Open (Bank 1)
Open of short in VSV for IACV circuit

VSV for IACV

ECM

P2102
(05±483)Throttle Actuator Control Motor
Circuit Low
Open in throttle control motor circuit

Throttle control motor

ECM

P2103
(05±483)Throttle Actuator Control Motor
Circuit High
Short in throttle control motor circuit

Throttle control motor

ECM

P2111
(05±485)Throttle Actuator Control System
± Stuck Open
Throttle control motor circuit

Throttle control motor
P2112
(05±485)Throttle Actuator Control System
± Stuck Closed
Throttle body

Throttle valve
P2118
(05±487)Actuator Control Motor Current
Range/Performance
Open in ETCS power source circuit

ECM
P2119
(05±490)Throttle Actuator Control Throttle
Body Range/Performance
Electric throttle control system

ECM
P2120
(05±492)Throttle/Pedal Position Sensor/
Switch ºDº Circuit
Open or short in accelerator pedal position sensor circuit

Accelerator pedal position sensor

ECM

P2121
(05±499)Throttle/Pedal Position Sensor/
Switch ºDº Circuit Range/Perfor-
mance
Open or short in accelerator pedal position sensor circuit

Accelerator pedal position sensor

ECM


05±300
± DIAGNOSTICSSFI SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
4. FAIL±SAFE CHART
If any of the following codes is recorded, the ECM enters into the fail±safe mode.
DTC No.Fail±Safe OperationFail±Safe Deactivation Conditions
P0031
P0032
P0037
P0038
P0051
P0052
P0057
P0058
Faulty heater circuit is turned off.Ignition switch is OFF.
P0100
P0102
P0103Ignition timing is calculated based on an engine speed and
a throttle opening angle.ºPassº detection has occurred. Upon this occurrence, the
ECM will return to normal mode.
P0105
P0107
P0108
Intake air pressure is controlled with a calculated value in
proportion to the throttle opening angle and the engine
speed.

Limit the engine speed to 3,000 rpm or less.
ºPassº detection has occurred. Upon this occurrence, the
ECM will return to normal mode.
P0110
P0112
P0113
Intake air temperature is fixed at 20 C (68 F)ºPassº detection has occurred. Upon this occurrence, the
ECM will return to normal mode.
P0115
P0117
P0118
Engine coolant temperature is fixed at 80   ºPassº detection has occurred. Upon this occurrence, the
ECM will return to normal mode.
P0120
P0121
P0122
P0123
P0220
P0222
P0223
P2135
Turn off the power for the throttle motor, return the throttle
valve in position using the return spring, and fuel cut inter-
mittent.Repeat the following conditions at least 2 seconds or more
with the throttle position switch closed:

VTA is more than 0.1 V but less than 0.95 V

Engine speed is 0 km/h
P0190
P0191
Stop the high±pressure pump operation.

Limit the engine speed to 2,000 rpm or less.After it is returned to normal condition, turn the ignition switch
ON.
P0200Turn off the INJ relay and cut the power for the EDU.
P0201
P0202
P0203
P0204
Stop fuel injection for an abnormal cylinder and related
other cylinders.

Limit the engine speed to 3,000 rpm or less.After it is returned to normal condition, turn the ignition switch
ON.
P0325
P0327
P0328
Maximum timing retardationIgnition switch is OFF.
P0351
P0352
P0353
P0354
Stop fuel injection for all the cylinders.ºPassº detection has occurred. Upon this occurrence, the
ECM will return to normal mode.
P0604
P0606
P0607
P0657Turn off the power for the throttle motor, return the throttle
valve in position using the return spring, and fuel cut inter-
mittent.After it is returned to normal condition, turn the ignition switch
ON.
P1235
Stop the high±pressure pump operation.

Limit the engine speed to 2,000 rpm or less.After it is returned to normal condition, turn the ignition switch
ON.
P2008Force IACV to close.After it is returned to normal condition, turn the ignition switch
ON.

±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
05±301
AVENSIS REPAIR MANUAL (RM1018E)DTC No.
Fail±Safe Deactivation Conditions
Fail±Safe Operation
P2102
P2103
P2111
P2112
P2118
P2119
Turn off the power for the throttle motor, return the throttle
valve in position using the return spring, and fuel cut inter-
mittent.After it is returned to normal condition, turn the ignition switch
ON.
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138

If both VPA1 and VPA2 are malfunctioning:
Fixed at idle

If either of VPA1 or VPA2 is malfunctioning:
Fuel cut intermittently
After it is returned to normal condition, turn the ignition switch
ON.
5.CHECK FOR INTERMITTENT PROBLEMS
Hand±held tester only:
By putting the vehicle's ECM in the check mode, the 1 trip detection logic is possible instead \
of the 2 trip
detection logic, and the sensitivity to detect faults is increased. This\
makes it easier to detect intermittent
problems.
(a)Clear the DTCs (See step 2).
(b)Set the check mode (See step 3).
(c)Perform a simulation test (See page 01±22).
(d)Check the connector and terminal (See page 01±32).
(e)Wiggle the harness and the connector (See page 01±32).
6. DATA LIST
HINT:
Using the DATA LIST displayed by the hand±held tester, you can read the value of the switches, sensors,
actuators and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one
method to shorten diagnostic time.
NOTICE:
The values given below for ºNormal Conditionº are representative valu\
es. A vehicle may still be nor-
mal even if its value differs from those listed here. So, do not solely dep\
end on the ºNormal Condi-
tionº here when deciding whether a part is faulty or not.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the hand±held tester to the DLC3.
(d) Turn the ignition switch ON.
(e) Push the ºONº button of the hand±held tester.
(f) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LISTº.
(g) According to the display on tester, read the ºDATA LISTº.
Hand±held Tester DisplayMeasurement Item/Range
(Display)Normal Condition *1Diagnostic Note
INJECTOR
Injection period of the No. 1 cylin-
der/
Min.: 0 ms, Max.: 32.64 ms
Idling: 0.40 to 0.78 ms

IGN ADVANCE
Ignition timing advance for No. 1
cylinder/
Min.: ±64 deg., Max.: 63.5 deg.
Idling: BTDC 5 to 23


CALC LOADCalculated load by ECM/
Min.: 0 %, Max.: 100 %
Idling: 21.6 to 31.4 %

Running without load (2,500
rpm): 19.6 to 29.4 %

05±302
± DIAGNOSTICSSFI SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)Hand±held Tester DisplayDiagnostic Note Normal Condition *
1Measurement Item/Range
(Display)
MAFAir flow rate from MAF sensor/
Min.: 0 gm/s, Max.: 655 gm/s
Idling: 3.2 to 4.7 gm/s

Running without load (2,500
rpm): 13.1 to 18.9 gm/s
If the value is Approximately 0.0
gm/s:

Mass air flow meter power
source circuit open

VG circuit open or short
If the value is 160.0 gm/s or more:

E2G circuit open
MAP
Absolute pressure inside intake
manifold/
Min.: 0 kPa, Max.: 224 kPa
Idling: 22 to 32 kPa

Running without load (2,500
rpm): 20 to 30 kPa
If the value is Approximately 0.0
kPa:

PIM circuit short
If the value is 142.0 kPa or more:

VC circuit open or short

PIM circuit open

E2 circuit open
ENGINE SPDEngine speed/
Min.: 0 rpm, Max.: 16383 rpmIdling: 625 to  rpm

COOLANT TEMPCoolant temperature/
Min.: ±40C, Max.: 140CAfter warming up: 80 to 95C (176
to 203
If the value is ±40C (±40F):

Sensor circuit is open.
INTAKE AIRIntake air temperature/
Min.: ±40C, Max.: 140CEquivalent to Ambient Temp.

Sensor circuit is oen.
If the value is 140C (284F):

Sensor circuit is shorted.
THROTTLE POSAbsolute throttle position sensor/
Min.: 0 %, Max.: 100 %
Throttle fully closed: 10 to 24 %

Throttle fully open: 64 to 96 %Read the value with ignition switch
ON (Do not start engine).
CTP SWClosed throttle position switch/
ON or OFF
Throttle fully closed: ON

Throttle open: OFF

VEHICLE SPDVehicle speed/
Min.: 0 km/h, Max.: 255 km/hActual vehicle speedSpeed indicated on speedometer
ACCEL POS #1
Accelerator pedal position sensor
No.1 output voltage/
Min.: 0 V, Max.: 5 V
Accelerator pedal released:
0.5 to 1.1 V

Accelerator pedal depressed:
2.5 to 4.6 V
Read the value with ignition switch
ON (Do not start engine).
ACCEL POS #2
Accelerator pedal position sensor
No.2 output voltage/
Min.: 0 V, Max.: 5 V
Accelerator pedal released:
1.5 to 2.9 V

Accelerator pedal depressed:
3.5 to 5.5 V
Read the value with ignition switch
ON (Do not start engine).
THROTTLE POS #2Throttle position sensor No.2 out-
put voltage/ Min.: 0 V, Max.: 5 V
Throttle fully closed: 2.1 to 3.1 V

Throttle fully open: 4.5 to 5.5 VRead the value with ignition switch
ON (Do not start engine).
THROTTLE TARGTTarget position of throttle valve/
Min.: 0 V, Max.: 5 VIdling: 0.4 to 1.1 V

THROTTLE OPN DUTYThrottle motor opening duty ratio/
Min.: 0 %, Max.: 100 %Throttle fully closed: 0 %

When accelerator pedal is de-
pressed, duty ratio is increased.

Read the value with ignition
switch ON (Do not start engine)
THROTTLE CLS DUTYThrottle motor closed duty ratio/
Min.: 0 %, Max.: 100 %Throttle fully closed: 0 %

When accelerator pedal is re-
leased quickly, duty ratio is in-
creased.

Read the value with ignition
switch ON (Do not start engine)
THROTTLE MOTWhether or not throttle motor con-
trol is permitted/ ON or OFFIdling: ON

+BM
Whether or not electric throttle
control system power is inputted/
ON or OFF
Idling: ON