TOYOTA AVENSIS 2003 Service Repair Manual

A78508
Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Throttle Body Assy
Throttle Motor Connector

Throttle Body Gasket
Water By±pass Hose No. 2
Water By±pass Hose No. 1
9.0 (90, 80 in.
lbf)
x4
x4
21 (210, 15)Throttle Body Bracket
8.4 (86, 74 in.
lbf)
Ground Terminal
Wire Harness Protector
8.4 (86, 74 in.
lbf)
10±48
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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A79577
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

Gasket Fuel Tube Sub±assy
Fuel Pipe Clamp
Fuel Pressure Pulsation
Damper Assy
Fuel Pump Assy

Fuel Pump
Insulator
Fuel HoseFuel pipe Sub±assy No. 1

Fuel Injector Back±up Ring No. 1
25 (255, 18)
33 (331, 24)
9.0 (92, 80 in.
lbf)
38 (388, 28)
30 (306, 22)

Fuel Injector Back±up Ring No. 2

Fuel Injector Back±up Ring No. 3


O±ring
Engine Cover Bracket
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
10±49
AVENSIS REPAIR MANUAL (RM1018E)
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A79597
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

Gasket
38 (388, 28)
21 (210, 15)
9.5 (97, 84 in.
lbf)
30 (306, 22)
9.8 (100, 7)
30 (306, 22)
30 (306, 22)
Union to Connector
Tube Hose
Vacuum Hose
Intake Manifold
Insulator No. 1
Intake Air Control Valve Assy
Intake Manifold Insulator No. 2
Surge Tank
Stay No. 1
Engine Cover Bracket Charcoal Canister Assy
Intake Manifold
x2
10±50
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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A79833N´m (kgf´cm, ft´lbf): Specified torque Knock Sensor
20 (204, 15)
±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
10±51
AVENSIS REPAIR MANUAL (RM1018E)
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100FA±01
A79596
A78436
10

10
Upper
Engine
Front
10±52
±
ENGINE CONTROL SYSTEMKNOCK SENSOR(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 18±16)
3.REMOVE ENGINE ROOM COVER SIDE (See page 18±17)
4.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±44)
5.DRAIN ENGINE COOLANT (See page 16±31)
6.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±44)
7.REMOVE THROTTLE BODY ASSY (See page 10±44)
8.REMOVE CHARCOAL CANISTER ASSY
9.REMOVE ENGINE COVER BRACKET (See page 11±52)
10.REMOVE FUEL PUMP ASSY (See page 11±52)
11.REMOVE INTAKE MANIFOLD (See page 11±42)
12.REMOVE SURGE TANK STAY NO.1 (See page 11±42)
13.REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11±42) 14.REMOVE KNOCK SENSOR
(a)Remove the nut and the knock sensor.
15.INSTALL KNOCK SENSOR
(a)Install the knock sensor with the nut as shown in the il-lustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
16.INSTALL INTAKE MANIFOLD INSULATOR NO.2 (See page 11±42)
17.INSTALL SURGE TANK STAY NO.1 (See page 11±42)
18.INSTALL INTAKE MANIFOLD (See page 11±42)
19.INSTALL FUEL PUMP ASSY (See page 11±52)
20. INSTALL ENGINE COVER BRACKET
(a) Install the engine cover bracket and the bolt. Torque: 38 N
m (388 kgf
cm, 28 ft
lbf)
21. INSTALL CHARCOAL CANISTER ASSY
22.INSTALL THROTTLE BODY ASSY (See page 10±44)
23.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±44)
24.ADD ENGINE COOLANT (See page 16±31)
25.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
26. CHECK FOR FUEL LEAKS
27. INSTALL ENGINE COVER SUB±ASSY NO.1
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1AZ±FSE)
10±53
AVENSIS REPAIR MANUAL (RM1018E)
28. INSTALL ENGINE ROOM COVER SIDE
29. INSTALL RADIATOR SUPPORT OPENING COVER
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100FF±01
A78505
A78502
A78506
Upper
30
30


±
ENGINE CONTROL SYSTEM KNOCK SENSOR (1ZZ±FE/3ZZ±FE)
10±17
AVENSIS REPAIR MANUAL (RM1018E)
KNOCK SENSOR (1ZZ±FE/3ZZ±FE)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
(a) Remove the 5 clips, 2 screws and bolt, and then remove
the engine under cover.
2. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Remove the nut, and then remove the knock sensor.
3. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the nut as shown in the il- lustration.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the knock sensor connector.
4. INSTALL ENGINE UNDER COVER SUB±ASSY NO.1
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100G7±02
321
45
±20
020 40 60
80100
0.1
0.2 0.3 0.5 1 2
35
10
20 30
TEMPERATURE
C(
F)
RESISTANCE k

(±4) (32) (80) (140)(104) (212)
(176)
Air
E2THAVG
E2G +B
A50378
12
Valve
A50377
B09641
10±20
±
ENGINE CONTROL SYSTEM SFI SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Output voltage inspection. (1) Apply battery voltage across terminals 1 (+B) and 2(E2G).
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (±) tester
probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the volt- age fluctuates.
(b) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween terminals 4 (THA) and 5 (E2).
Resistance:
TerminalsResistanceTemperature
THA ± E213.6 to 18.4 k
±20
C (±4
F)
THA ± E22.21 to 2.69 k
20
C (68
F)
THA ± E20.49 to 0.67 k
60
C (140
F)
2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance: 6.9 to 7.9
at 20
C (68
F)
(b) Movement inspection. (1) Connect the positive (+) lead from the battery to ter-minal 1 and negative (±) lead to terminal 2, and
check the movement of the valve.
NOTICE:
Confirm the valve does not adhere.
HINT:
Bad returning of the valve by entrance of foreign objects causes
subtle pressure leak to the advanced direction. Then, DTC can
be detected.
3. INSPECT THROTTLE BODY ASSY
(a) Check throttle body. (1) Check that throttle valve shaft is not rickety.
(2) Check that each port is not stopped up.
(3) Check that throttle valve opens and closes smooth-
ly.
(4) Check that there is no clearance between the
throttle stop screw and throttle lever when the
closed throttle position.
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VTA E2 VC
A35493
±
ENGINE CONTROL SYSTEM SFI SYSTEM (1AZ±FE)
10±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) Adjust the throttle stop screw.
NOTICE:
The throttle stop screw adjusting is very, so adjust it only
when the adjusting is really needed.
(1) Loosen the locknut and loosen the screw until it de-taches the lever.
(2) Confirm that the throttle vale is fully closed.
(3) After the screw touches the lever, tighten it by 1/4
revolution additionally and tighten the lock nut.
(4) Seal the lock nut with yellow paint.
(5) Check that the throttle position sensor operates normally.
4. INSPECT THROTTLE POSITION SENSOR
(a) Resistance inspection. (1) Disconnect the throttle position sensor connector.
(2) Using an ohmmeter, measure the resistance be-tween terminals VC and E2.
Resistance: 2.5 to 5.0 k

(3) Check the change of resistance between terminals VTA and E2.
Change of resistance:
The resistance value increases in proportion to the
throttle lever opening value.
HINT:
Throttle valveResistance
Fully close0.2 to 5.7 k

Fully open2.0 to 10.2 k

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TEMPERATURE
C(
F)
RESISTANCE k
30
20
10
5
2
1
0.5
0.3
0.2
0.1 3
±20 0 20 40 60 80 100
(±4) (32) (80) (140)(104)
(212)
(176)
A50371
A65174
Ohmmeter
E34090
10±22
±
ENGINE CONTROL SYSTEM SFI SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
5. INSPECT ENGINE COOLANT TEMPERA TURE
SENSOR
(a) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-tween each terminal.
Resistance:
Approx. 20
C (68
F) 2.32 to 2.59k
Approx. 80
C (176
F) 0.310 to 0.326k 
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.
6. INSPECT KNOCK SENSOR
(a) Using an ohmmeter, measure the resistance between ter- minals.
Resistance: 120 to 280 k at 20
C (68
F)
HINT:
If the resistance is not specified, replace the sensor.
7. INSPECT EFI RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuitybetween 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 continuitybetween terminals 3 and 5.
Specified condition: Continuity
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