TOYOTA AVENSIS 2002 Repair Manual

100F0±02
321 4 5
±20
020 40 60
80100 0.1 0.2 0.3 0.51 235 1020 30
TEMPERATURE
C(
F)
RESISTANCE k

(±4) (32) (80) (140)(104) (212)(176)
A56275
VG
E2G
THA +B E2 Air
A31135
10±56
± ENGINE CONTROL SYSTEMECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Output voltage inspection.
(1) Apply battery voltage across terminals 3 (+B) and 4
(E2G)
(2) Using a voltmeter, connect the positive (+) tester
probe to terminal VG, and negative (±) tester probe
to terminal E2G.
(3) Blow air into the air flow meter, and check that the
voltage fluctuates.
(b) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-
tween terminals 2 (THA) and 1 (E2).
Resistance:
±20
C (±4
F) 12.5 to 16.9 k

20
C (68
F) 2.19 to 2.67 k

60
C (140
F) 0.50 to 0.68 k

2. INSPECT INTAKE SHUTTER ASSY
(a) Resistance inspection (Throttle control motor)
(1) Using an ohmmeter, measure the resistance be-
tween terminals.
Resistance:
TerminalsTemperatureResistance
2 ± 1, 3at 20
C (68
F)18 to 22 k

5 ± 4, 6at 20
C (68
F)18 to 22 k




30
20
10
5
3
02040 0.11
0.3
0.2 0.52
60 80 100 ±20
(±4) (104) (140) (176)(32) (68) (212)
Z17274
Ohmmeter
Acceptable
Temperature
C (
F)
Resistance k

THF E2
A30331
30
20
10




0.5
0.3
0.2
0.1
±20

20 4060
80 100
F14741(±4) (104) (140) (176)(32) (68) (212)
A56276
Temperature
C (
F)
Resistance k

± ENGINE CONTROL SYSTEMECD SYSTEM (1CD±FTV)
10±57
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT DIESEL ENGINE ENGINE COOLANT
TEMPERATURE SENSOR
(a) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-
tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.32 to 2.59 k

Approx. 80
C (176
F) 0.310 to 0.326 k

NOTICE:
In case of checking the water temperature sensor in the wa-
ter, be careful not to allow water to go into the terminals,
and after checking, wipe out the sensor.
4. INSPECT INJECTION OR SUPPLY PUMP ASSY
(a) Resistance inspection. (Fuel temperature sensor)
(1) Using an ohmmeter, measure the resistance be-
tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.21 to 2.69 k

Approx. 80
C (176
F) 0.287 to 0.349 k

5. INSPECT DIESEL TURBO INLET AIR TENPERATURE
SENSOR
(a) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-
tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.21 to 2.65 k

A56277
NE± NE+
A57060
NE± NE+
B16200
10±58
± ENGINE CONTROL SYSTEMECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
6. INSPECT CRANKSHAFT POSITION SENSOR
(a) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-
tween terminals.
Resistance:
at cold 1630 to 2740

at hot 2065 to 3225

NOTICE:
ºColdº and ºHotº in the following sentences express the
temperature of the sensor itself. ºColdº is from ±10
C
(14
F) to 50
C (122
F) and ºHotº is from 50
C (122
F) to
100
C (212
F).
7. INSPECT CAMSHAFT POSITION SENSOR
(a) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-
tween terminal.
Resistance:
at cold 1630 to 2740

at hot 2065 to 3225

NOTICE:
ºColdº and ºHotº in the following sentences express the
temperature of the sensor itself. ºColdº is from ±10
C
(14
F) to 50
C (122
F) and ºHotº is from 50
C (122
F) to
100
C (212
F).
8. INSPECT EDU RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
Specified condition: Continuity
(2) Check that there is no continuity between terminals
3 and 5.
Specified condition: No continuity
(b) Inspect the relay operation.
(1) Apply battery voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
Specified condition: Continuity

B16200
A31135
± ENGINE CONTROL SYSTEMECD SYSTEM (1CD±FTV)
10±59
AVENSIS REPAIR MANUAL (RM1018E)
9. INSPECT EFI MAIN RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
Specified condition: Continuity
(2) Check that there is no continuity between terminals
3 and 5.
Specified condition: No continuity
(b) Inspect the relay operation.
(1) Apply battery voltage across terminals 1 and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
Specified condition: Continuity
10. INSPECT ACCELERATOR PEDAL ASSY
(a) Inspect the accel position sensor.
(1) Using an ohmmeter, measure the resistance be-
tween each terminal.
Resistance:
RHD:
Between terminalResistance
5 (VPA1) ± 1 (EP1)5.0 kor less
2 (VPA2) ± 3 (EP2)5.0 kor less
4 (VCP1) ± 1 (EP1)1.5 to 6.0 k
6 (VCP2) ± 3 (EP2)1.5 to 6.0 k
LHD:
Between terminalResistance
3 (VPA1) ± 4 (EP1)5.0 kor less
6 (VPA2) ± 5 (EP2)5.0 kor less
2 (VCP1) ± 4 (EP1)1.5 to 6.0 k
1 (VCP2) ± 5 (EP2)1.5 to 6.0 k

100EZ±02
A75903
Air
A53763
VG
EVG
10±54
±
ENGINE CONTROL SYSTEM ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ECD SYSTEM(1CD±FTV)
ON±VEHICLE INSPECTION
1.INSPECTMASS AIR FLOW METER
(a)If you have hand±held tester: Inspect for operation
(1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON.
(3)Blow air into the MAF meter, and check that the airflow fluctuates (MAF ) of the CURRENT DATA
shown the standard value.
If operation is not as specified, check the MAF meter (See page
10±56), wiring and ECM.
(b)If you have no hand±held tester: Inspect for operation
(1)Turn the ignition switch ON.
(2)Connect the positive tester probe of the voltmeterto the terminal VG of the ECM. and the negative tes-
ter probe of the voltmeter to the terminal EVG of the
ECM.
(3)Blow air into the MAF meter, and check that the volt- age fluctuates.
If operation is not as specified, check the MAF meter (See page
10±56), wiring and ECM.
2.INSPECT INTAKE SHUTTER
(a)Inspect the throttle control motor for operating sound. (1)Turn the ignition switch ON.
(2)When turning the accelerator pedal position sensor lever, check the running sound of the motor.
Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See page 10±56), wiring and ECM.
(b)Inspect the throttle position sensor. (1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON.
(3)When turning the accelerator pedal position sensor lever to the full±\
open position, check thatthe throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the
standard value.
Standard throttle valve opening percentage:
60 % or more
If operation is not as specified, check that the accelerator pedal positio\
n sensor (See page 10±56), wiring
and ECM.
If you have no hand±held tester, measure voltage between terminals (LU+A ± LU±A, LU+B ± LU±\
B) of the
ECM connector (See page 05±549).

±
ENGINE CONTROL SYSTEM ECD SYSTEM(1CD±FTV)
10±55
AVENSIS REPAIR MANUAL (RM1018E)
(c)Inspect the air assist system.
(1)Start the engine and check that the CHKENG does not light up.
(2)Allow the engine to warm up to normal operating temperature.
(3)Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 800
50 rpm
NOTICE:
Perform inspection under condition without electrical load.
(d)After checking the above (b) to (d), perform the driving test and check that there is no sense of incon- gruity.
3.INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON.
(c)Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value. Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depress: 2.6 to 4.5 V
(d)Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value.
Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depress: 3.4 to 5.3 V
If you have no hand±held tester, measure voltage between terminals (VPA1 ± EP1, VPA2 ± EP2) of the ECM
connector (See page 05±549).

100FR±01
A79186
±
ENGINE CONTROL SYSTEM ECM
10±65
AVENSIS REPAIR MANUAL (RM1018E)
ECM
REPLACEMENT
HINT:
1CD±FTV Engine Type:
Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes
which are used to optimize fuel injection for the injectors. When replacing t\
he ECM, the compensation codes
must be set to the new ECM.
1.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
2.REMOVE ECM
(a)Disconnect the 4 ECM connectors (1ZZ±FE, 3ZZ±FE,1AZ±FE, 1CD±FTV).
(b)Disconnect the 5 ECM connectors (1AZ±FSE).
(c)Disconnect the wire harness clamp.
(d)Remove the bolt and screw, then remove the ECM.
(e)Remove the 2 screws and the ECM bracket No. 1 from the ECM.
(f)Remove the 2 screws and the ECM bracket No. 2 from the ECM.
3.INSTALL ECM Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
4.INSTALL GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
5.REGISTRATION OF INJECTOR COMPENSATION CODE (1CD±FTV ENGINE TYPE) (See page 05±528)

100FN±01
A79433N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
Gasket
25 (255, 18)
25 (255,18 )
21 (214, 15)
30 to 40 (31 to 41 , 27 to 35 in.
lbf)
5.0 (51, 44 in.
lbf)
8.0 (82, 71 in.
lbf)
Radiator Support Opening Cover Engine Cover No. 1
Battery
Battery Tray
Intake Shutter Assy
Air Hose No. 4
Clip
Retainer
Air Tube No. 2
10±60
± ENGINE CONTROL SYSTEMINTAKE SHUTTER ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE SHUTTER ASSY (1CD±FTV)
COMPONENTS

100FO±01
A80092
B08171
A64328
2 to 7 mm0 to 4 mm
± ENGINE CONTROL SYSTEMINTAKE SHUTTER ASSY (1CD±FTV)
10±61
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
3. REMOVE BATTERY
4. REMOVE AIR HOSE NO.4
(a) Loosen the 2 hose clamps.
(b) Remove the 2 bolts and separate the air tube No. 2.
(c) Remove the air hose No. 4.
5. REMOVE INTAKE SHUTTER ASSY
(a) Disconnect the 2 connectors.
(b) Remove the 3 nuts, then remove the intake shutter and
the gasket.
6. INSTALL INTAKE SHUTTER ASSY
(a) Install a new gasket and the intake shutter with the 3 nuts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
7. INSTALL AIR HOSE NO.4
(a) Install the air hose No. 4 to the air tube No. 2.
(b) Install the air tube No. 2 with the 2 bolts.
Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
(c) Install the air hose and hose clamp as shown in the il-
lustration.

A64007
Front
90

Clamp
Bolt 10±62
± ENGINE CONTROL SYSTEMINTAKE SHUTTER ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Tighten the hose clamp as shown in the illustration.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
8. INSTALL ENGINE COVER NO.1
(a) Install the engine cover with the 5 nuts.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
9. INSTALL BATTERY
Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt
3.0 to 4.0 N
m (31 to 41 kgf
cm, 27 to 35 in.
lbf) for nut