2005 TOYOTA AVENSIS service

FI0534
A76859
Hand±Held Tester
05±152
±
DIAGNOSTICS SFI SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E) Terminal No.
Connection / Voltage or ResidenceCondition
7Bus + Line / Pulse generation+During transmission
4Chassis Ground ± Body Ground / 1

or lessAlways
16Battery Positive± Body Ground / 9 to 14 VAlways
HINT:
If the display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the hand±held tester to
the DLC3, turned the ignition switch ON and operated the
hand±held tester, there is a problem on the vehicle side or tool
side.

If communication is normal when the tool is connected to
another vehicle, inspect the DLC3 on the original vehicle.

If communication is still impossible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Deparment listed in the
tool's instruction manual.
(d)Inspect the battery voltage.
Battery voltage: 11 to 14 V
If voltage is below 11V, recharge the battery before proceeding.
(e)Check the CHK ENG. (1)The CHK ENG lamp comes on when the ignitionswitch is turned ON and the engine is not running.
HINT:
If the CHK ENG lamp is not illuminated, troubleshoot the com-
bination meter. (2)When the engine is started, the CHK ENG shouldgo off. If the lamp remains on, it means that the diag-
nosis system has detected a malfunction or ab-
normality in the system.
2.DTC CHECK (Nomal Mode) :
NOTICE:
Hand±held tester only:
When the diagnosis system is switched from the normal
mode to the check (test) mode, it erases all DTCs and freeze
frame data recorded in the normal mode. So before switch-
ing modes, always check the DTCs and freeze frame data,
and then write them down.
(a)Checking DTCs using the hand±held tester. (1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON and switch the hand±held tester main switch ON.
(3)Use the hand±held tester to check the DTCs and freeze frame data and then write them down. The
hand±held tester's instruction book.
(4)See page 05±161 to confirm the details of the DTCs.

D25148
DLC3 12345 768
9 1 0111 21 3 1 514 16
FI2547
05±986± DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
(6) *2 trip detection logic:
When a malfunction is first detected, the malfunc-
tion code is temporarily stored in the ECM memory
(1st trip). If the same malfunction is detected again
during the second drive test, this second detection
causes the CHK ENG (MIL) to illumenate (2nd trip)
(However, the ignition switch must be turned OFF
between the 1st trip and the 2nd trip.).
(b) Inspect the DLC3.
(1) The vehicle's ECM uses ISO 9141±2 (Euro±OBD)
communication protocol. The terminal arrangement
of DLC3 complies with ISO 15031±3 and matches
the ISO 9141±2 format.
Terminal No.ConnectionVoltage or ResistanceCondition
7Bus
LinePulse generationDuring communication
4Chassis Ground
Body Ground / 1
or lessAlways
16Battery Positive
Body Ground / 9 to 14 VAlways
HINT:
If your display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of hand±held tester to
DLC3, turned the ignition switch ON and operated the hand±
held tester, there is a problem on the vehicle side or tool side.

If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.

If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool's instruction manual.
2. INSPECT DIAGNOSIS (NORMAL MODE)
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not come on, troubleshoot the combination me-
ter.
(2) When the engine is started, the MIL should go off.
If the light remains on, the diagnosis system has de-
tected a malfunction or abnormality in the system.

031H4−02
− SERVICE SPECIFICATIONSCOOLING
03−21
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−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
Fan assy w/ motor x Radiator6.06153 in.
lbf
Radiator relay block x Radiator5.05446 in.
lbf
1CD−FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST
Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Fuel inlet pipe sub−assy x Common rail assy
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe sub−assy x Injection pump
With SST
Without SST
31
34316
34723
25
Timing belt idler Sub−assy No.1 x Cylinder head3535726
Front wheel1031,05076

031H3−02
03−20
− SERVICE SPECIFICATIONSCOOLING
AVENSIS Supplement (RM1045E)
COOLING
SERVICE DATA
2AZ−FSE:
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
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
Cooling fan
Standard amperage at 20_C (68_F)
Standard amperage (No. 2) at 20_C (68_F)
8.5 to 11.5 A
5.2 to 8.2 A
Cooling fan relay
Specified condition Between terminals 3 and 5
Cooling fan relay No. 2
Specified condition Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No. 3
Specified condition Between terminals 3 and 5
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
Below 1

10 k
or higher (Apply battery voltage terminals 1 and 2)
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
10 k
or higher
Below 1
(Apply battery voltage terminals 1 and 2)
1CD−FTV:
Thermostat
Valve opening temperature
Valve lift at 95_C (203_F)
80 to 84_C (176 to 183_F)
8.5 mm (0.335 in.) or more
Radiator cap sub−assy
Standard opening pressure
Minimum opening pressure
93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.4 psi)

031E3−03
− SERVICE SPECIFICATIONSEXHAUST
03−19
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold converter sub−assy4344032
Exhaust pipe assy center x Exhaust pipe assy front4344032
Exhaust pipe assy tail x Exhaust pipe assy center434432
Floor panel brace front x Body3030222
1CD−FTV:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy front x Tail pipe assy4344032
Floor panel brace front x Body3030222
Air fuel ratio sensor x Exhaust pipe assy front4444933

031E2−03
03−18
− SERVICE SPECIFICATIONSEXHAUST
AVENSIS Supplement (RM1045E)
EXHAUST
SERVICE DATA
2AZ−FSE:
Compression spring (Exhaust pipe assy front x Exhaust manifold converter
sub−assy)
Free length Minimum
41.5 mm (1.634 in.)
Compression spring (Exhaust pipe assy tail x Exhaust pipe assy center)
Free length Minimum
38.5 mm (1.516 in.)
1CD−FTV:
Compression spring
Minimum length Exhaust pipe assy front x Exhaust manifold
41.5 mm (1.634 in)
Compression spring
Minimum length Exhaust pipe assy front x Tail pipe assy
38.5 mm (1.515 in)

031H2−02
03−14
− SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−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
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
Water by−pass pipe No. 3 x Cylinder block9.09280 in.
lbf
Oil cooler pipe x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
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
Exhaust manifold heat insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Drive plate & ring gear 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 Bolt
Nut45
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
Engine mounting bracket x No. 2 RH x Transverse engine
engine mounting insulator A
B
52
11 3530
1,15238
83
Vane pump assy x Timing chain cover3737027
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 RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD 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 Sub−assy x Body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 5
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Engine cover No. 1 x Cylinder head cover9.09280 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90 _806
Turn 90 _58
Turn 90 _
Camshaft timing oil control valve assy x Cylinder head9.09279 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Battery carrier x Frame131319.5
Battery clamp x Body Bolt
Nut5.0
3.551
3644 in. lbf
31 in. lbf
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 −45) 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
1 CD −FTV:
Part TightenedN
mkgf
cmft
lbf
Air tube No. 1 hose clamp bolt6.06153 in.
lbf
Air tube No. 1 x Air tube No. 22525518
Air tube No. 1 x Intake air connector2525518
Air tube No. 1 x Cylinder head cover sub −assy2525518
Air tube No. 1 x Engine mounting bracket FR2525518
Engine cover No. 1 x Cylinder head cover sub −assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel1031,05076
Drain plug (Manual transaxle)4950036
Engine hanger No.1 x Cylinder head3737727
Engine hanger No.2 x Cylinder head3737727
Engine hanger No. 1 UPR x Engine hanger No. 13737727
Engine coolant temperature sensor x Cylinder head2020014
Crankshaft position sensor x Oil pump assy8.89078 in.
lbf
Camshaft position sensor x Camshaft oil seal retainer8.89078 in.
lbf
Fuel filler to injection pump fuel pipe x Cylinder block M6
M88.82190
20978 in.
lbf
15
Oil cooler pipe x Cylinder block5657542
Compressor mounting bracket x Cylinder block4242831
Timing belt No.3 cover x Cylinder head7.47565 in.
lbf