TOYOTA AVENSIS 2005 Service Repair Manual

A88284Battery
A13269B12608
A91714
Hand−held Tester
11 −6
−
FUEL FUEL SYSTEM (2AZ −FSE)
AVENSIS Supplement (RM1045E)
(b) When not using the hand −held tester.
(1) Connect the positive (+) lead form the battery to ter- minal 4 of the connector, and connect the negative
(− ) lead to terminal 5.
(2) Check that the pump operates.
3. CHECK FUEL PUMP OPERATION (HIGH PRESSURE)
(a) Remove the engine cover No. 1 (see page 10 −8) .
(b) Start the engine.
(c) Using a sound scope, hear the operating sound of the pump.
If there is no sound, replace the fuel pump.
(d) Stop the engine.
(e) Reinstall the engine cover No. 1 (see page 10 −8) .
4. CHECK FUEL HIGH PRESSURE
(a) Connect the hand −held tester to the DLC3.
(b) Start the engine.
(c) Select the ACTIVE TEST mode on the hand −held tester.
(d) Perform the ACTIVE TEST check the fuel high pressure at idle to 3,000 rpm.
Fuel high pressure:
9.5 to 10.5 Mpa (97 to 107 kgf/cm
2, 1,380 to 1,520 psi)
If the pressure is not as specified, check the fuel pump, high
pressure fuel pump, fuel pressure sensor, wiring and fuel leak-
age.
(e) Stop the engine.
(f) Disconnect the hand −held tester.

100LT−01
A79186
−
ENGINE CONTROL SYSTEM ECM (From September, 2003)
10−29
AVENSIS Supplement (RM1045E)
ECM (From September, 2003)
REPLACEMENT
NOTICE:
1CD −FTV Engine Type:
S If an incorrect injector compensation code was registered with the ECM, it may rattle the engine
assembly or the engine idling may become rough. In addition, it may become a cause of engine
failure or shorten the life of the engine.
S If you replace the ECM with a new one, register all the injectors’ injector compensation codes
with the new ECM as follows:
( a) Pri or t o repl aci ng t he ECM , r ead al l t he compensat i on codes st ored i n t he exi st i ng ECM
using the hand −held tester, then write them down (see page 05 −273).
(b) After replacing the ECM, enter the written compensation codes into the ECM using the hand −
held tester (see page 05 −277).
(c) Turn the ignition switch to OFF, then wait for 30 seconds or more.
(d) Turn the ignition switch to ON, then clear DTC P1601 using the hand −held tester
(see page 05 −290).
HINT:
S In order to optimize the injector ’s fuel injection characteristic, the ECM compensates the injection dura-
tion by each cylinder. The ECM stores and uses compensating data in the form of a 30 −digit −alphanu-
meric value that is imprinted on the head portion of each injector as the injector compensation code.
S If you installed a new injector, its own injector compensation code is needed to register with the ECM.
Also, if you replaced the ECM, the compensation codes of all the injectors are needed to register be-
cause the new ECM does not have the codes until they are registered.
S Once the ECM is replaced, DTC P1601 will be present when turning the ignition switch to ON. This
is to inform you that the injector compensation codes are required to register with the ECM. In order
to clear the DTC, register the compensation codes first, then turn the ignition switch to OFF and wait
for 30 seconds or longer.
1. REMOVE GLOVE COMPARTMENT DOOR ASSY (See Pub. No. RM1018E on page 71 −11 )
2. REMOVE ECM
(a) Disconnect the 4 ECM connectors (1ZZ −FE, 3ZZ −FE,
1AZ −FE, 1CD −FTV).
(b) Disconnect t he 5 ECM connect or s ( 1AZ −FSE, 2AZ −
FSE).
(c) Disconnect the wire harness clamp.
(d) Remove the bolt and screw, then remove the ECM.
(e) Remove the 2 screws and ECM bracket No. 1 from the ECM.
(f) Remove the 2 screws and 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 Pub. No. RM1018E on page 71 −11 )
5. REGISTRATION OF INJECTOR COMPENSATION CODE (1CD −FTV ENGINE TYPE)
(See page 05 −277)
6. CLEAR DTC (1CD −FTV ENGINE TYPE)
(a) Turn the ignition switch to OFF, then wait for 30 seconds or longer.
(b) Turn the ignition switch to ON, then clear DTC P1601 using the hand −held tester
(see page 05 −290).

100FO−02
A80092
(b)(a)
(a)
(b)
A85751
A64328
2to7mm0to4mm
(0.08 to 0.28
in.)(0 to 0.16
in.)
− ENGINE CONTROL SYSTEMINTAKE SHUTTER ASSY (1CD−FTV)(From September,
2003)10−27
AVENSIS Supplement (RM1045E)
Removal & Installation and Disassembly & Reassembly
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE COVER SUB−ASSY NO.1
(a) Remove the 5 nuts and engine cover.
3. REMOVE BATTERY
4. REMOVE AIR HOSE NO.4
(a) Loosen the 2 hose clamps.
(b) Remove the 2 bolts, then 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
gasket.
6. INSTALL INTAKE SHUTTER ASSY
(a) Install a new gasket and the intake shutter with the 3 nuts.
Torque: 21 N
m (209 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 clamps as shown in the il-
lustration.

A64007
Front
90_
Clamp
Bolt 10−28
− ENGINE CONTROL SYSTEMINTAKE SHUTTER ASSY (1CD−FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(d) Tighten the hose clamps as shown in the illustration.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
8. INSTALL ENGINE COVER SUB−ASSY 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

100M3−01
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) (68) (140)(104) (212)(176)
A89885
THA VG
E2G+B
E2
A86426
VTA
VC E2
10−22
− ENGINE CONTROL SYSTEMECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the operation.
(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 MAF meter, then check that the
voltage fluctuates.
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween terminals 2 (THA) and 1 (E2).
Resistance:
12.5 to 16.9 k
at−20_C(−4_F)
2.19 to 2.67 k
at 20_C (68_F)
0.50 to 0.68 k
at 60_C (140_F)
If the result is not as specified, replace the MAF meter.
2. INSPECT INTAKE SHUTTER ASSY
(a) Inspect the resistance of the throttle position sensor.
(1) Using an ohmmeter, measure the resistance be-
tween terminals 1 (VC) and 2 (E2).
Resistance: 4.0 to 8.0 k

If the result is not as specified, replace the intake shutter.

S01196S01699
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
5
3
2
1
0.5
0.3
0.2
0.1
−20 0
20 4060
80 100
F14741(−4) (104) (140) (176)(32) (68) (212)
A56276
Temperature_C(_F)
Resistance k

− ENGINE CONTROL SYSTEMECD SYSTEM (1CD−FTV)(From September, 2003)
10−23
AVENSIS Supplement (RM1045E)
3. INSPECT DIESEL ENGINE ENGINE COOLANT
TEMPERATURE SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
2.32 to 2.59 k
at 20_C (68_F)
0.310 to 0.326 k
at 80_C (176_F)
If the result is not as specified, replace the diesel engine engine
coolant temperature sensor.
NOTICE:
In case of checking the water temperature sensor in the wa-
ter, be careful not to allow water to go into the terminals. Af-
ter checking, wipe out the sensor.
4. INSPECT FUEL TEMPERATURE SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
2.21 to 2.69 k
at 20_C (68_F)
0.287 to 0.349 k
at 80_C (176_F)
If the result is not as specified, replace the fuel temperature sen-
sor.
5. INSPECT DIESEL TURBO INLET AIR TENPERATURE
SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
2.21 to 2.65 k
at 20_C (68_F)
If the result is not as specified, replace the diesel turbo inlet air
temperature sensor.

A56277
NE−NE+
A57060
NE− NE+
B16200
10−24
− ENGINE CONTROL SYSTEMECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
6. INSPECT CRANKSHAFT POSITION SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
1630 to 2740
at cold
2065 to 3225
at hot
If the result is not as specified, replace the crankshaft position
sensor.
NOTICE:
”Cold” and ”Hot” in the above sentences mean the temper-
ature of the sensor itself. ”Cold” is from−10_C (14_F) to
50_C (122_F) and ”Hot” is from 50_C (122_F) to 100_C
(212_F).
7. INSPECT CAMSHAFT POSITION SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
1630 to 2740
at cold
2065 to 3225
at hot
If the result is not as specified, replace the camshaft position
sensor.
NOTICE:
”Cold” and ”Hot” in the above sentences mean the temper-
ature of the sensor itself. ”Cold” is from−10_C (14_F) to
50_C (122_F) and ”Hot” is from 50_C (122_F) to 100_C
(212_F).
8. INSPECT EDU RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Specified condition:
Tester ConnectionSpecified Condition
3−510 k
or Higher
3−5
Below 1

(When battery voltage is applied to
terminals 1 and 2)
If the result is not as specified, replace the EDU relay.

B16200
A31135
RHD:
VPA2
VPA1 EP2EP1
VCP2 VCP1
A31135
LHD:
VPA2
VPA1 EP1EP2
VCP1 VCP2
− ENGINE CONTROL SYSTEMECD SYSTEM (1CD−FTV)(From September, 2003)
10−25
AVENSIS Supplement (RM1045E)
9. INSPECT EFI MAIN RELAY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Specified condition:
Tester ConnectionSpecified Condition
3−510 k
or Higher
3−5
Below 1

(When battery voltage is applied to
terminals 1 and 2)
If the result is not as specified, replace the EFI main relay.
10. INSPECT ACCELERATOR PEDAL ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
RHD:
Tester ConnectionSpecified Condition
5 (VPA1)−1 (EP1)5.0 k
or less
2 (VPA2)−3 (EP2)5.0 k
or less
4 (VCP1)−1 (EP1)1.5 to 6.0 k

6 (VCP2)−3 (EP2)1.5 to 6.0 k

LHD:
Tester ConnectionSpecified Condition
5 (VPA1)−3 (EP1)5.0 k
or less
2 (VPA2)−1 (EP2)5.0 k
or less
6 (VCP1)−3 (EP1)1.5 to 6.0 k

4 (VCP2)−1 (EP2)1.5 to 6.0 k

If the result is not as specified, replace the accelerator pedal as-
sembly.

100M2−01
A75903
Air
A66060
VG
EVGE12 ECM Connector
−
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD−FTV)(From September, 2003)
10 −19
AVENSIS Supplement (RM1045E)
ECD SYSTEM (1CD −FTV)(From September, 2003)
ON −VEHICLE INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) If you have the hand −held tester:
Check the operation.
(1) Connect the hand −held tester to the DLC3.
(2) Turn the ignition switch to ON.
(3) Select the item ”DIAGNOSIS / OBD / MOBD / DATA
LIST” on the hand −held tester.
(4) Blow air into the mass air flow (MAF) meter, then
check that the MAF reading in DATA LIST fluctu-
ates.
If the operation is not as specified, check the MAF meter
(see page 10 −22), wiring and ECM.
(b) If you have no hand −held tester:
Check the operation.
(1) Turn the ignition switch to ON.
(2) Connect the positive tester probe of a voltmeter to
terminal VG of the ECM, and the negative tester
probe of the voltmeter to terminal EVG of the ECM.
(3) Blow air into the MAF meter, then check that the voltage fluctuates.
If the operation is not as specified, check the MAF meter
(see page 10 −22), wiring and ECM.
2. INSPECT INTAKE SHUTTER
(a) Listen to the operating sounds of the throttle control mo- tor.
(1) Turn the ignition switch to ON.
(2) Listen to the operating sounds while turning the ac-
celerator pedal position sensor lever.
If a collision sound is heard, check the throttle control motor.
If no sound is heard, check the wire harness and ECM.
(b) If you have the hand −held tester:
Inspect the throttle position sensor.
(1) Connect the hand −held tester to the DLC3.
(2) Turn the ignition switch to ON.
(3) Select the item ”DIAGNOSIS / OBD / MOBD / DATE LIST” on the hand held −tester.

A66060
E12
ECM Connector
E1
LUSL
A92422
Signal Waveform
10 msec./Dvision
10
−20
−
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(4) When turning the accelerator pedal position sensor lever t o t he f ull − open posit ion, check t hat t he
t hr ot t le v alve opening per cent age ( THRO TTLE
POS) of DATA LIST shows the standard value.
Standard throttle valve opening percentage:
60 % or higher
If the operation is not as specified, check the accelerator pedal
position sensor (see page 10 −22), wiring and ECM.
(c) If you have no hand −held tester:
(1) Inspect the throttle position sensor using a oscillo- scope.
(2) During idling, check the waveform between the spe- cified terminals of the E12 ECM connectors.
Standard:
Tester ConnectionSpecified Condition
LUSL (E12 −4) − E1 (E12 −7)Correct waveform is as shown on the left
If the operation is not as specified, check the accelerator pedal
position sensor (see page 10 −22), wiring and ECM.
(d) Inspect the air assist system.
(1) Start the engine, then check that the check engine warning light does not light up.
(2) Allow the engine to warm up to the normal operating
temperature.
(3) Turn the A/C compressor ON to OFF, then check the
idle speed (see page 14 −87).
Idle speed (transmission in neutral): 800 á50 rpm
If the result is not as specified, check the wiring and ECM.
NOTICE:
Perform the inspection under condition without electrical
load.
(e) After taking the above steps (b) to (c), perform the driving test.
(f) Check that there is no sense of incongruity.