Toyota Avensis T250 2003-2009 service repair workshop manual pdf download

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File type: PDF / File size: 48MB / Pages: 2049
Language: English
Toyota Avensis Second generation series T250 (2003–2009)[edit]
Production2003–2009
Body and chassis
Body style4-door saloon
5-door liftback
5-door estate
PlatformToyota 'T'
RelatedScion tC
Toyota Premio
Toyota Allion
Dimensions
Wheelbase2,700 mm (106.3 in)
LengthEstate: 4,715 mm (185.6 in)
Others: 4,645 mm (182.9 in)
Width1,760 mm (69.3 in)
HeightEstate: 1,525 mm (60.0 in)
Others: 1,480 mm (58.3 in)
UK-spec 2004 Avensis
The second generation Toyota Avensis (model code T250) was launched in early 2003 in an all-new format; this time it offered more in the way of driver involvement and visual appeal. Like the Toyota Echo and Toyota Corolla, it was penned by the company's design studio in France.[3] The 1.6, 1.8 and 2.0-litre petrol and 2.0-litre turbodiesel engines were carried over from the previous Avensis, and the 2.4-litre four-cylinder from the Camry was also added to the range. This was the first Avensis to be exported to Japan. Due to the Camry Wagon ending production, the Avensis Wagon is exported to New Zealand, in both 1.8 and 2.0-litre forms. In Britain, there were no 1.6 versions available.
In the 2004 European Car of the Year contest, the Avensis came in fourth place behind the; Fiat Panda (Winner), Mazda3 (Second) and the Volkswagen Golf (Third). However, it won the 2004 Semperit Irish Car of the Year. What Car? also awarded the Avensis as the 'Best Family Car' for 2004 and 2005.
Following the withdrawal of the Toyota Camry in 2004 (2005 in Switzerland), the Avensis became the largest Toyota saloon sold in Europe.
Trim levels in the UK are the T2, T3-S, T3-X, T4, T Spirit, T180 and the TR. There is also a special edition, based on the T2 called the Colour Collection. In Ireland there were five trim levels – Terra, Aura, Strata, Luna, and Sol.
The original 115 PS (85 kW) D-4D Diesel engine has been complemented with a 2.2 L D-4D in 136 PS (2AD-FTV) and 177 PS (2AD-FHV) versions. Newer versions have dropped the 'D-4D' and '2.0' badging from the front wings and tailgate respectively.
In Japan, the Avensis is sold as 2.0 Xi, 2.0 Li, and 2.4 Qi. Only the base model 2.0 Xi is offered with 4-wheel drive.
In 2003, the Avensis became the first Japanese vehicle to receive a 5/5 stars rating under the Euro NCAP's redone testing, with 34 total points it also became the highest rated vehicle they had tested.[4] The 2003 Avensis also became the first vehicle sold in Europe with a knee airbag.[5]
This is first and only one generation of Avensis sold in Egypt and Morocco, not in Persian Gulf countries.
From 2005, the 2.4L version was fitted with a 5 speed automatic transmission.
The Avensis Verso continued to be available alongside the new Avensis until 2006. A replacement to take over from the Avensis Verso, Toyota Previa and Toyota Sienna has yet to be unveiled, but is rumoured to feature Toyota's 2.2-litre D-4D engine.
The new facelifted Toyota Avensis became available in June 2006. Some changes from the old model are the inclusion of turn signals in the side mirrors, an MP3/WMA/ASL-ready audio system, new front bumper, and a new grille. Interior materials and cloth seats have also been changed for 2006. Its multi display with on-board computer will be integrated in optitron display and is navigation ready. Also added are automatic headlights and a height-adjustable front passenger seat.
The most notable mechanical difference is the addition of a 124 bhp (92 kW) D-4D engine. This, coupled to a six-speed manual gearbox, has lowered fuel consumption, emissions, and gives a quoted 0–60 mph time of 10.5 seconds.
Engines
1.6-litre VVT-i 3ZZ-FE 81 kW (109 hp)
1.8-litre VVT-i 1ZZ-FE 95 kW (127 hp)
2.0-litre VVT-i 1AZ-FSE 108 kW (145 hp)
2.4-litre VVT-i 2AZ-FSE 120 kW (161 hp)
2.0-litre D-4D 1CD-FTV 85 kW (114 hp)
2.0-litre D-4D 1AD-FTV 93 kW (125 hp)
2.2-litre D-4D 2AD-FTV 110 kW (148 hp)
2.2-litre D-4D 2AD-FHV 130 kW (174 hp)

Toyota Avensis 2003 2004 2005 2006 2007 2008 ZZT250, ZZT251, AZT250, AZT251 ADT250 ADT251 CDT250 Clutch

Description

Clutch system with the following features.

• A dry, single-plate clutch operated by hydraulic pressure is used, which is matched to the performance of each engine.

• The clutch pedal has a turnover mechanism to reduce clutch pedal effort on the 1AZ-FE, 1AZ-FSE and 1CD-FTV engine models.

• The 1CD-FTV engine model has an inline accumulator in the pipe to the clutch. In this application, the accumulator reduces the vibration that is transmitted to the clutch pedal.

• A flywheel damper is used to reduce the noise and vibration of the drive train on the 1CD-FTV engine.

Toyota Avensis T25 Workshop Manual

The following describes the changes from the previous model to the new model:

• The clutch master cylinder changed of the cylinder body and piston materials. (old material Aluminum, new material Plastic)

• The clutch start system has been adopted to ensure safety newly on the 1AZ-FSE and Avensis (CDT250) 2,0TD 16V (1CD-FTV) engine models in the Europe, and on the 1AZ-FE engine model in General Countries.

ZZT250 ZZT251

AZT250

CDT250

Specification

Engine Type		1ZZ-FE and 3ZZ-FE	1AZ-FE and 1AZ-FSE	1CD-FTV
Clutch	Type	Dry Type Single-Plate Clutch Diaphragm Spring
	Operation	Hydraulic
Clutch Cover	Type	DST Diaphragm Spring Turnover
	Size mm (in.)	212(8.35)	224 (8.82)224
	Installed Load	4800N (1ZZ-FE) 4300N (3ZZ-FE)	5200N	7440N
Clutch Disk	Facing Size Outer Diameter x Inner Diameter x Thickness mm (in.)	212x140x3.3 (8.35x5.51x0.13)	224x150x3.4 (8.82x5.91x0.13)
	Facing Area cm2 (in.2)	199(30.3)	217(33.6)
Master Cylinder	Type	Non-Adjustable
Release Cylinder	Cylinder Diameter mm (in.)	22.2 (0.87)	20.64 (0.81)
Clutch Accumulator		without	without	with
Clutch Pedal		Conventional	Turnover
Clutch Start System		without	without 1AZ-FE for Europe with 1AZ-FSE engine in the Europe and only for 1AZ-FE engine in General Countries	with

Clutch master cylinder

A clutch master cylinder made of plastic is used to reduce weight.

Toyota Avensis T25 Repair Manual Diagram

Parts: Body (Plastic), Spring, Piston (Plastic), Push Rod and Clevis

This master cylinder cannot be disassembled, so it must be replaced as an assembly. For details, see the Avensis Repair Manual (Pub. No. RM1018E)

Clutch start system

The system prevents the starter from cranking unless the clutch pedal is depressed. By thus preventing the engine from being started in gear, this system ensures safety by preventing the vehicle from starting off unintendedely.

Toyota Avensis T25 Service & Repair Manual

System Diagram

Toyota Avensis T25 Repair Manual Transmission

Clutch Start Switch, Engine ECU, Ignition Switch, ST Relay, Starter