2005 TOYOTA AVENSIS head removal

Illustration:
what to do and where
Component part No. Detailed text: how to perform task
Task heading: what to do
Set part No
D31009
01±2
± INTRODUCTIONHOW TO USE THIS MANUAL
AVENSIS REPAIR MANUAL (RM1018E)
(c) Tightening torque, grease application area, and non±reusable parts are described as important points
in the procedures.
NOTICE:
There are cases where such information can only be explained by using an illustration. In these
cases, all the information such as torque, oil, etc. are described in the illustration.
(d) Installing procedures are performed in the reverse order of the removal and only the important points
are described.
(e) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notices are placed.
(f) There may be a case where the illustrations of similar models are used. In that case, specific details
may be different from the actual vehicle.
(g) The procedures are presented in a step±by±step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task and gives other information such as specifica-
tions and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary and the text below provides detailed information. Important
specifications and warnings always are written in bold type to stand out from the rest of the text.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for quick reference.
6. TERMS DEFINITION
CAUTIONIndicates the possibility of injury to you or other people.
NOTICEIndicates the possibility of damage to the components being repaired.
HINTProvides additional information to help you to perform the repair efficiently.

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.

100FC±01
A784575 Claws
A78458
A78459
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY(1ZZ±FE)
10±9
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support
opening cover.
2.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±7)
4. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, and then remove the cylin- der head cover No. 2.

5000C±14
±
STEERING COLUMN STEERING SYSTEM
50±1
AVENSIS REPAIR MANUAL (RM1018E)
STEERING SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Be careful to replace the parts properly because they could affect the performance of the steering sys-
tem and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as \
the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence \
could cause the SRS
to unexpectedly deploy during servicing, possibly leading to a serious acc\
ident. Before servicing (in-
cluding removal or installation of parts, inspection or replacement), be sure \
to read the precautionary
notices in the supplemental restraint system (See page 60±1).
3. HANDLING PRECAUTIONS ON STEERING COLUMN
(a) Do not give an impact to the steering column assy, especially the motor and the torque sensor. If a great impact is given (dropping it to the floor, etc.), replace it with a new one.
(b) When removing the steering column assy, do not pull the harness.
(c) When having replaced the steering column assy and/or the ECU, calibrate the \
zero point of the steer- ing torque sensor.
(d) In the case of disconnecting a connector related to the power steering sys\
tem, turn the ignition switch ON, set the steering wheel in the straight±ahead position and turn th\
e ignition switch OFF before dis-
connecting the connector.
(e) In the case of connecting a connector related to the power steering system, make sure that the ignit\
ion switch is OFF at first. After connecting the connector, set the steering wheel assy in the straight±ahead
position, and then turn the ignition switch ON.
NOTICE:
Never turn on the ignition switch when the steering wheel assy is set in orde\
r than the straight±ahead
position.
(f) If the above operation is not done, the zero point of the steering torque \
sensor is shifted away from the proper position, making difference in the steering effort between right and left. If this happens, per-
form the zero point calibration of the steering torque sensor (See page 05±1042).

H42657
H42659
60±14
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTRUMENT PANEL AIRBAG ASSY (VEHICLE IN- VOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the instrument panel airbag assy re- moved from the vehicle:

Cuts, minute cracks or marked discoloration on the
instrument panel airbag assy.
HINT:

Never repair it in order for reuse or replacement.

There should be no interference between the horn button
assy and steering wheel assy, and the clearance should
be uniform all the around when the new horn button assy
is installed on the steering wheel assy.
CAUTION:
For removal and installation procedures of the horn button
assy, see ºReplacementº on page 60±54, and be sure to fol-
low the correct procedure.
11. AIRBAG SENSOR ASSY CENTER (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
12. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
13. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a)Replace the airbag sensor assy center (See page 60±62).
14. AIRBAG FRONT SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
15. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the headlamp of the vehicle or its periphery is damaged, check if t\
here is any damage to the airbag front sensor. If there are any defects as mentioned below, replace the airbag front sensor with
a new one:
If there are any defects as mentioned below, replace the airbag front sensor with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
16. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the airbag front sensor assy (See page 60±64).
17. SIDE AIRBAG SENSOR ASSY (VEHICLES NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).

700TA±01
B68025
Clip
Piano Wire
B69236
Protective Tape
BO4421
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
70±41
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1.REMOVE BACK DOOR TRIM BOARD ASSY (See page 75±45)
(a) Remove the back door trim panel upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE REAR SPOILER (See page 76±30)
3.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to prevent the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around it.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
5. CLEAN BACK DOOR GLASS
(a) Clean the outer circumference of the glass with white gas- oline.
NOTICE:

Do not touch the glass surface after cleaning it.

Be careful not to damage the body.

700T8±01
B68025
Piano Wire
Clip
B69235
Protective Tape
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
70±35
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1.REMOVE BACK DOOR TRIM BOARD ASSY (See page 75±40)
(a) Remove the back door trim panel assy upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE CENTER STOP LAMP ASSY (See page 65±26)
3.REMOVE REAR WIPER MOTOR ASSY (
See page 66±17)

(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to prevent the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around the glass.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.

700T6±01
B50453
CutCut
B62805
Stopper
Piano Wire
70±28
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1 . REMOVE REAR SE AT CUSHION ASSY ( See page 72±27 or 72±32 )
2 . REMOVE REAR SE ATBACK ASSY ( See page 72±27 or 72±32 )
3 . REMOVE ROOF HEADLINING ASSY ( See page 76±36)
(a) Remove the rear door weatherstrip LH.
(b) Remove the rear door weatherstrip RH.
(c) Remove the roof side garnish inner LH.
(d) Remove the roof side garnish inner RH.
(e) Remove the 2 assist grips.
(f) Remove the rear map lamp.
(g) Remove the roof headlining assy.
4 . REMOVE CENTER S TOP LAMP ASSY ( See page 65±26)
5 . REMOVE P ACKAGE TR AY TRIM P ANEL ASSY ( See page 61±15 )
6. REMOVE BACK WINDOW MOULDING OUTSIDE UPPER
(a) Using a knife, cut off the moulding, as shown in the il- lustration.
NOTICE:
Do not damage the vehicle body with the knife.
(b) Remove the remaining moulding.
HINT:
When removing, make a partial cut, then pull and remove it by
hand.
7. REMOVE BACK WINDOW GLASS
(a) Pass a piano wire between the vehicle body and glass
from the interior.
(b) Tie both wire ends to wooden blocks or similar objects.