2005 TOYOTA AVENSIS engine coolant

14−84
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
AVENSIS Supplement (RM1045E)
94. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
95. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
96. INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11 −24)
97. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
98. INSTALL VANE PUMP ASSY Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
99. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −2)
100. INSTALL GENERATOR ASSY (See page 19 −8)
101. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
102. ADD COOLANT (See page 16 −7)
103. ADD ENGINE OIL (See page 17 −6)
104. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
105. CHECK FOR ENGINE OIL LEAKS
106. CHECK FOR FUEL LEAKS (See page 11 −4)
107. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
108. ADD POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
109. BLEED POWER STEERING FLUID (See Pub. No. RM1018E on page 51 −4)
110. CHECK POWER STEERING FULUID LEVEL IN RESERVOIR
(See Pub. No. RM1018E on page 51 −4)
111. CHECK FUNCTION OF THROTTLE BODY

A89211
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part zO−ringzGasket zBack−Up Ring No. 1
20 (208, 15)
21 (210, 15)21 (210, 15)
20 (208, 15)
Engine Coolant
Temperature Sensor
Engine Oil Pressure
Switch Assy
Surge Tank Stay No. 1
Insulator No. 2
zE−ring
zBack−Up Ring No. 3
zFuel Injector Seal
13 (127, 9.0)
Fuel Delivery
Pipe Sub−assy
Nozzle Holder Clamp
Knock Sensor
15 (153, 11)
Fuel Injector
zBack−Up Ring No. 2zO−ring19 (194, 14)
14−22
− ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)

1308N−01
A84393
(a)
(b)
(a)
(a)
(b)
A93661
(a)
(a) (a)
(a) (b)
(a)
(b)
13
−12
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
2. DRAIN ENGINE COOLANT (See page 16 −19)
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE COVER SUB −ASSY NO.1
(a) Remove the 5 nuts and engine cover.
5. REMOVE VACUUM RESERVOIR SUB −ASSY
(a) Disconnect the 2 vacuum hoses and connector.
(b) Remove the 2 bolts and vacuum reservoir.
6. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
7. DISCONNECT ENGINE WIRE (See page 14 −138)
8. REMOVE AIR CLEANER ASSY
(a) Disconnect the PCV hose and connector.
(b) Remove the air cleaner cap with the air cleaner hose.
(c) Remove the air cleaner filter element.
(d) Remove the 3 bolts and air cleaner case.
9. REMOVE AIR TUBE NO.1
(a) Remove the 3 bolts and nut, then separate the air tubeNo. 1.
(b) Loosen the hose clamp bolts.
10. REMOVE FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)

A84387
2to7mm
(0.0787 to
0.2756 in.) 0to5mm
(0 to 0.1969 in.) 0to2mm
(0 to 0.0787 in.) *1*2
*2: *1:
Turbocharger Side
Intercooler Side
A93662
Turbocharger Side:
Intercooler Side: Upward
90_
Cl a m p
Bolt
90_
Cl a m p
Bolt
Front
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)13 −19
AVENSIS Supplement (RM1045E)
53. INSTALL AIR TUBE NO.1
(a) Install the air hose and hose clamps as shown in the il-
lustration.
(b) Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
54. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
55. INSTALL AIR CLEANER ASSY
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
56. INSTALL VACUUM RESERVOIR SUB −ASSY
Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
57. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
58. ADD ENGINE COOLANT (See page 16 −19)
59. CHECK ENGINE OIL LEVEL
60. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
61. CHECK FOR ENGINE OIL LEAKS
62. CHECK FOR FUEL LEAKS (See page 11 −46)
63. CHECK FOR EXHAUST GAS LEAKS

160MQ−02
A56451
A77424
10 _10_
Jiggle Valve
16 −14
−
COOLING THERMOSTAT (2AZ −FSE)
AVENSIS Supplement (RM1045E)
THERMOSTAT (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER INLET
(a) Remove the 2 nuts and water inlet.
10. REMOVE THERMOSTAT 11. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat while aligning the jiggle valve withits right position described in the illustration.
HINT:
The jiggle valve may be set within 10 _ of either side of the pre-
scribed position.
12. INSTALL WATER INLET Torque: 9.0 N
m (92 kgf
cm, 7 in.
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

160MR−02
B12054
SST
B12052
B12053
Pry
PryPry
16
−12
−
COOLING WATER PUMP ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
WATER PUMP ASSY (2AZ −FSE)
REPLACEMENT
1. DRAIN COOLANT (See page 16 −7)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
3. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
4. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
5. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
7. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
8. REMOVE GENERATOR ASSY (See page 19 −8)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and pump pulley. SST 09960 −10010 (09962 −01000, 09963 −00700)
(b) Disconnect the crankshaft position sensor wire clamp
from the water pump.
(c) Disconnect the crankshaft position sensor wire from the clamp on the water pump.
10. REMOVE WATER PUMP ASSY
(a) Remove the 4 bolts, 2 nuts, wire clamp and water pump.
(b) Using a screwdriver, pry out between the water pump and cylinder block, and remove the water pump.
NOTICE:
Be careful not to damage the contact surface of the water
pump and cylinder block.

A57664
Seal Width
2.2 to 2.5 mm0.5 to 1.0 mm
B12052
B12054
SST
−
COOLING WATER PUMP ASSY (2AZ −FSE)
16 −13
AVENSIS Supplement (RM1045E)
11. INSTALL WATER PUMP ASSY
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump assy.
(b) Apply a continuous bead of the seal packing (diameter 2.2 to 2.5 mm (0.09 to 0.10 in.)) as shown in the illustra-
tion.
Seal packing: Part No. 08826 − 00100 or equivalent
NOTICE:
Install the water pump assy within 5 minutes after applying
seal packing. Otherwise the material must be removed and
reapplied.
(c) Install the water pump and wire clamp with 4 bolts and 2 nuts.
Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(d) Install the crankshaft position sensor wire harness clamp
to the water pump.
(e) I nst all t he cr ankshaf t posit ion s ensor wir e t o t he wir e clamp on the water pump.
12. INSTALL WATER PUMP PULLEY
(a) Using SST, install the pump pulley with 4 bolts. SST 09960 −10010 (09962 −01000, 09963 −00700)
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
13. INSTALL GENERATOR ASSY (See page 19 −8)
14. INSTALL FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
15. ADD COOLANT (See page 16 −7)
16. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)

05JOB–03
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–21
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
FAIL–SAFE CHART
If any of the following DTCs are recorded, the ECM enters fail–safe mode.
DTC No.Fail–Safe OperationFail–Safe Deactivation Condition
P0031
P0032Heated oxygen sensor (Sensor 1) heater is turned offIgnition switch turned to OFF
P0037
P0038Heated oxygen sensor (Sensor 2) heater is turned offIgnition switch turned to OFF
P0100
P0102
P0103Ignition timing is calculated from engine RPM and Throttle
Position (TP)”Pass” condition detected
P0110
P0112
P0113
Intake Air Temperature (IAT) is fixed at 20
C (68
F)”Pass” condition detected
P0115
P0117
P0118
Engine Coolant Temperature (ECT) is fixed at 80
 
”Pass” condition detected
P0120
P0122
P0123
P0220
P0222
P0223
P2102
P2103
P2111
P2112
P2118
P2119
P2135
When Electronic Throttle Control System (ETCS) is mal-
functioning, electric current to throttle actuator is cut off and
throttle valve returns to throttle position (TP) 16 by its
spring.
Then, required engine power is calculated using ignition
timing and Accelerator Pedal Position (APP). Engine is
controlled by intermittent fuel–cut.
As a result, fully slowly depressing accelerator pedal en-
ables driving at minimum speed. However, quickly depress-
ing pedal would vary vehicle speed remarkably.
”Pass” condition detected followed by the ignition switch
turned to OFF
P0121Fuel is cut intermittently”Pass” condition detected followed by the ignition switch
turned to OFF
P0325
P0327
P0328
Maximum ignition timing retardationIgnition switch turned to OFF
P0351
P0352
P0353
P0354
Fuel is cut”Pass” condition detected
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138
Accelerator Pedal Position (APP) sensor has main circuit
and associate circuit. When one of circuits is malfunction-
ing, APP is calculated by output of other circuit. When both
of circuits are malfunctioning, it is interpreted that accelera-
tor pedal is releasing. As a result, throttle valve is closed
and engine idles.
”Pass” condition detected followed by the ignition switch
turned to OFF