2005 TOYOTA AVENSIS service

03−1 6
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Intake manifold x Cylinder head2120915
Power steering idle pulley bracket x Cylinder head
(See page 14 −108) Bolt A
Bolt B
72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
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
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe x injection pump With SST
Without SST
31
34316
34723
25
Nozzle leakage pipe No.2 x Cylinder head cover sub −assy8.89078 in.
lbf
Nozzle leakage pipe No.2 x Cylinder head8.89078 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2120915
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub −assy x Cylinder head2120915
Exhaust manifold x Cylinder head4747434
EGR pipe sub −assy x Cylinder head Bolt
Nut37
25375
25027
18
Vacuum pump oil pipe x Cylinder block Bolt Nut21
8.8214 9015
78 in.
lbf
Vacuum transmitting pipe No. 2 x Manifold converter
For nut With SST
Without SST
For bolt
27
30
25275
306
25520
22
18
Vacuum transmitting pipe No. 1 x Manifold converter
For nut With SST Without SST
For bolt
27
30
25275
306
25520
22
18
Exhaust gas temperature sensor x Manifold converter With SST
Without SST27
30275
30620
22
Exhaust gas temperature sensor x Vacuum transmitting pipe No. 26.46557 in.
lbf
Oil filter bracket x Oil pan sub −assy3434725
V −ribbed belt tensioner bracket x Cylinder block2020415
V −ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub −assy x V −ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub −assy center x Body4545933

−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03−1 7
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Front suspension crossmember sub −assy x Rear engine mounting bracket8788764
Front suspension crossmember sub −assy x Front engine mounting bracket5253038
Front suspension crossmember sub −assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub −assy1331,35698
Front suspension member brace x Body8081659
Return tube sub −assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting blacket5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Air tube No. 2 hose clamp bolt Intake shutter side
Air hose No. 3 side6.0
5.361
5453 in.
lbf
47 in.
lbf
Injector driver x Engine mounting insulator RH5.55649 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay block x Radiator assy5.35447 in.
lbf
Differential pressure sensor x Body5.55649 in.
lbf
Air cleaner assy x Body x Engine mounting bracket LH7.07162 in.
lbf
Battery clamp x Body Body
Nut5.0
3.0 to 4.051
31 to 4144 in.
lbf
27 to 35 in.
lbf
Battery terminal5.45548 in.
lbf
Timing belt tensioner x Cylinder block2121415
Timing chain cover plate x Camshaft oil seal retainer9.09280 in.
lbf
Transverse engine engine mounting bracket x
Cylinder block (See page 14 −138) Bolt A
Bolt B
37
64375
65027
47
Timing belt No. 1 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 1 cover x Oil pump assy7.47565 in.
lbf
Timing belt No. 2 cover x Transverse engine engine mounting bracket7.47565 in.
lbf
Timing belt No. 2 cover x Cylinder head cover sub −assy7.47565 in.
lbf
Timing belt No. 2 cover x Camshaft oil seal retainer7.47565 in.
lbf
Timing belt No. 2 cover x Timing belt cover No. 37.47565 in.
lbf
Crankshaft pulley x Crankshaft1801,835133
Camshaft bearing cap x Cylinder head2020415
Camshaft oil seal retainer x Cylinder head9.81007.2
Camshaft timing pulley x Camshaft8889965
Nozzle leakage pipe x Injector1616312
Nozzle leakage pipe x Camshaft bearing cap No. 42020415
Cylinder head cover x Cylinder head131359.7
Vacuum reservoir sub −assy x Cowl top panel outer8.38573 in.
lbf
Cylinder head x Cylinder block 1st
2nd3rd4th45
Turn 90 _
Turn 90 _
Turn 90 _459
Turn 90 _
Turn 90 _
Turn 90 _33
Turn 90 _
Turn 90 _
Turn 90 _
Exhaust fuel addition injector x Cylinder head1211 78.5
Drain plug (oil pan)3435025

05−1 8
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
S 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 Department listed in the
tool’s instruction manual.
4. INSPECT BATTERY VOLTAGE Battery voltage: 11 to14V
If voltage is below 11 V, recharge the battery before proceeding.
5. CHECK CHK ENG
(a) The CHK ENG c om es on when t he ignit ion swit ch is turned to ON and the engine is not running.
HINT:
If the CHK ENG is not illuminated, troubleshoot the CHK ENG
circuit (see page 05 −25 1).
(b) When the engine is started, the CHK ENG should not illu- minate. If the lamp remains on, the diagnosis system has
detected a malfunction or abnormality in the system.

0313C−07
− SERVICE SPECIFICATIONSTIRE & WHEEL
03−29
AVENSIS Supplement (RM1045E)
TIRE & WHEEL
SERVICE DATA
Engine type:
2AZ−FSE
Tire sizeFront
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
Cold tire inflation pressure
205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
215/45R17 87W:
with 4 or less occupants
with 5 or more occupants220 (2.2, 32)*1
250 (2.5, 36)*2
220 (2.2, 32)*1
270 (2.7, 39)*2
240 (2.4, 35)*1
290 (2.9, 42)*2
240 (2.4, 35)*1
310 (3.1, 45)*2
220 (2.2, 32)*1
250 (2.5, 36)*2
220 (2.2, 32)*1
280 (2.8, 41)*2
240 (2.4, 35)*1
290 (2.9, 42)*2
240 (2.4, 35)*1
330 (3.3, 48)*2
Tire runout1.4 mm (0.055 in.) or less
Imbalance after adjustment8.0 g (0.018 lb) or less
*1: For driving under160 km/h (100 mph)
*2: For driving at160 km/h (100 mph) or over

031E5−02
− SERVICE SPECIFICATIONSIGNITION
03−25
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Ignition coil assy x Cylinder head cover sub−assy9.09280 in.
lbf
Spark plug x Cylinder head sub−assy1919414
Camshaft position sensor x Cylinder head sub−assy9.09279 in.
lbf
Wire harness protector x throttle body bracket8.48674 in.
lbf
Engine wire No. 3 (battery negative terminal) x Battery5.45548 in.
lbf
Crankshaft position sensor x Timing chain cover sub−assy9.09279 in.
lbf

C52361DLC3
FI0534
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −289
AVENSIS Supplement (RM 1045E)
S Freeze frame data
Freeze frame data records the engine conditions when a
malfunction is detected. When troubleshooting, freeze
frame data can help determine if the vehicle was running
or stopped, if the engine was warmed up or not, if the air −
fuel ratio was lean or rich, and other data from the time the
malfunction occurred.
2. CHECK DLC3
(a) The v ehicle’s ECM uses t he I SO 9 1 41− 2( Eur o −OBD)
communication protocol. The terminal arrangement of
the DLC3 complies with ISO 1503 1− 03 and matches the
ISO 9 141− 2 format.
SymbolTerminal No.NameReference TerminalResultCondition
SIL7Bus ”+” line5− Signal groundPulse generationDuring transmission
CG4Chassis groundBody ground1
or lessAlways
SG5Signal groundBody ground1
or lessAlways
BAT16Battery positiveBody ground9to 14VAlways
HINT:
Connect the cable of the hand −held tester to the DLC3, turn the
ignition switch to ON and attempt to use the hand −held tester.
If the screen displays UNABLE TO CONNECT TO VEHICLE,
a problem exists in the vehicle side or the tester side.
S If the communication is normal when the tool is connected
to another vehicle, inspect the DLC3 on the original ve-
hicle.
S If the communication is still impossible when the tool is
connected to another vehicle, the problem is probably in
the tester itself, so consult the Service Department listed
in its instruction manual.
3. INSPECT BATTERY VOLTAGE Battery voltage: 11 to14V
If voltage is below 11 V, recharge the battery before proceeding.
4. CHECK CHK ENG
(a) The CHK ENG comes on when the ignition switch is turned to the ON position and the engine is not running.
HINT:
If the CHK ENG is not illuminated, troubleshoot the combination
meter circuit (see page 05 −299).
(b) When the engine is started, the CHK ENG should turn off. If the CHK ENG illuminates again, the diagnosis system
has detected a malfunction or abnormality in the system.

3 2 145678
910111213141516
DLC33 2 145678
910111213141516
DLC33 2 145678
910111213141516
DLC3
A04550
− DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U151E)05−555
AVENSIS Supplement (RM1045E)
SFreeze frame data:
The freeze frame data records the engine conditions (fuel
system, calculated load, engine coolant temperature, fuel
trim, engine speed, vehicle speed, etc.) when a malfunc-
tion is detected. When troubleshooting, freeze frame data
can help determine if the vehicle was running or stopped,
if the engine was warmed up or not, if the air−fuel ratio
was lean or rich, and other data from the time the malfunc-
tion occurred.
3. CHECK DLC3.
(a) The vehicle’s ECM uses the ISO 9141−2 (Euro−OBD)/
ISO14230(M−OBD) communication protocol. The termi-
nal arrangement of the DLC3 complies with ISO
15031−03 and matches the ISO 9141−2/ ISO14230 for-
mat.
SymbolTerminal No.NameReference TerminalResultCondition
SIL7Bus ”+” line5−Signal groundPulse generationDuring transmission
CG4Chassis groundBody ground1
or lessAlways
SG5Signal groundBody ground1
or lessAlways
BAT16Battery positiveBody ground9to14VAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of hand−held tester to the
DLC3, turned the ignition switch to the ON position and oper-
ated the hand−held tester, there is a problem on the vehicle side
or tool side.
SIf communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
SIf 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.
4. INSPECT BATTERY VOLTAGE
(a) Measure the battery voltage.
Battery Voltage:11to14V
If the voltage is below11V, recharge the battery before pro-
ceeding.

1111 7−01
A78441zNon−reusable part
N·m (kgf·cm, ft·lbf) : Specified torqueSeat Fixed Type:
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Connector
Fuel Evaporation Tube
Sub−assy No. 2 Fuel Tank Main Tube
Sub−assy
Tube Joint ClipzFuel Pump Gauge Retainer
Fuel Suction
w/ Pump & Gauge Tube Assy
zFuel Suction Tube
Set Gasket x4
Fuel Tank Return Tube
11−28− FUELFUEL SUCTION W/ PUMP & GAUGE TUBE
ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (2AZ−FSE)
COMPONENTS