2005 TOYOTA AVENSIS radiator cap

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

± SERVICE SPECIFICATIONSCOOLING
03±25
AVENSIS REPAIR MANUAL (RM1018E) Cooling fan
Standard amperage at 20
C (68
F)
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 (203
F)
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 (68
F)
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)

±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E)Part Tightened
ft
lbf
kgf
cm
N
m
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body
w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A
Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN
mkgf
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

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

A77879
45

A77880
83.8 mm
(3.299 in.)
Rotation
Center of
Throttle Link
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1AZ±FE)
10±29
AVENSIS REPAIR MANUAL (RM1018E)
11.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that throttle valve is fully closed.
(b)With the throttle position sensor rotated 45
counter-
clockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure
it with the 2 screws.
12.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 3 screws.
13.INSTALL FUEL VAPOR FEED HOSE NO.2
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the fuel pipe support with the 3 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the fuel tube to the fuel pipe support.
(d)Connect the water by±pass hose.
(e)Connect the water by±pass hose No. 2.
(f)Connect the ISC valve connector.
(g)Connect the throttle position sensor connector.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Instal the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
16.INSTALL AIR CLEANER CAP SUB±ASSY
17.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±19)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER

100FG±01
A77870
Mass Air Flow
Meter Connector
N´m (kgf´cm, ft´lbf) : Specified torqueEngine Cover Sub±assy
No. 1
7.0 (71, 62 in.
lbf)
Fuel Vapor Feed Hose
No. 2
Air Cleaner Cap
Sub±assyVSV
Connector Fuel Vapor Feed Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip
Retainer
x2
x4 10±24
± ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
THROTTLE BODY ASSY (1AZ±FE)
COMPONENTS

100FE±01
A78497
A78498
(a)
(b)
(c)
A78499
(d)
(e)
A78500
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
10±15
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
3.DRAIN ENGINE COOLANT (See page 16±7)
4.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
5.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±9)
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator controlcable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the ventilation hose.
(b) Disconnect the water by±pass hose.
(c) Disconnect the water by±pass hose No. 2.
(d) Disconnect the throttle position sensor.
(e) Disconnect the ISC valve connector.
(f) Remove the bolt and 2 nuts, and then remove the acceler- ator control bracket and the throttle body.
(g) Remove the gasket from the intake manifold.
8. REMOVE ISC VALVE
(a) Remove the 4 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.

A78501
A78503
30
to 45

A78469
66.3 mm
(2.610 in.)
Rotation
Center of
Throttle Link
11

10±16
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE THROTTLE POSITION SENSOR
(a)Remove the 2 screws, and then remove the throttle posi- tion sensor.
10.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that the throttle valve is fully closed.
(b)With the throttle position sensor rotated 30
to 45
coun-
terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
11.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 4 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
12.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the accelerator control brack- et with the bolt and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
13.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
14.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±9)
15.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
16.ADD ENGINE COOLANT (See page 16±7)
17.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
18. INSTALL ENGINE ROOM COVER SIDE
19. INSTALL RADIATOR SUPPORT OPENING COVER