check engine light TOYOTA AVENSIS 2002 User Guide

A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90

Front
A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7 11
10
9
A10079
14±88
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
52. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(b) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90
in the same se-
quence as step (b).
(e) Check that the paint mark of each bolt is at 90
angle to
the front.
53. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in
the illustration.
(c) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque:
23 N
m (235 kgf
cm, 17 ft
lbf) for Bearing cap No. 1
13 N
m (133 kgf
cm, 10 ft
lbf) for Bearing cap No. 3
54. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the camshafts using a wrench to align the tim-
ing marks of the 2 camshaft timing sprockets.

A65677
A
A
AA
A
A
AAA B
B
B
A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±91
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the timing chain cover with the 11 bolts and nut.
Torque:
13 N
m (133 kgf
cm, 10 ft
lbf) for A
19 N
m (194 kgf
cm, 14 ft
lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)
60. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O±ring is clean, and set the hook as shown
in the illustration.
(b) Apply engine oil to the chain tensioner and install it with
the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
61. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O±ring on the
crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

140D1±02
CG
TCA51075
A52004
±
ENGINE MECHANICAL ENGINE(1AZ±FE)
14±101
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±13)
2.INSPECT ENGINE OIL (See page 17±6)
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±9)
6. INSPECT V±RIBBED BELT
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand±held tester:(1) Connect the hand±held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF.
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.

TA C
A52006
A13304
14±102
± ENGINE MECHANICALENGINE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 15 BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 650 to 750 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester.
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 650 to 750 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
(e) Inspect cylinder compression pressure.
SST 09992±00500
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.

141CP±01
CG
TCA51075
A79034
±
ENGINE MECHANICAL ENGINE(1AZ±FSE)
14±181
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FSE)
INSPECTION
1.INSPECT COOLANT (See page 16±25)
2.INSPECT ENGINE OIL(See page 17±13)
3.INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68 F)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±14)
6.INSPECT V±RIBBED BELT
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040, 09843±18020
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.

TA C
A52006
14±182
± ENGINE MECHANICALENGINE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 23 BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 625 to 725 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 625 to 725 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.

140KR±02
A62199
TCCG
A62200
±
ENGINE MECHANICAL ENGINE(1ZZ±FE/3ZZ±FE)
14±1
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1ZZ±FE/3ZZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±1)
2.INSPECT ENGINE OIL (See page 17±1)
3.INSPECT BATTERY (See page 19±5)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±3)
6.INSPECT FAN AND GENERATOR V BELT
HINT:
You don't need to check the belt deflection because auto tensioner is ado\
pted.
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:
(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12 BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester: (1) Using SST, connect terminal 13 (TC) and 4 (CG) ofthe DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the 2 nuts, and 2 clips, and then remove the cylinder head cover.
(3) Pull out the wire harness as shown in the illustration.
(4) Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.

TA C
A52006
A01037
14±2
± ENGINE MECHANICALENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Inspect ignition timing at idle.
Ignition timing: 8 to 12BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.
(6) Disconnect the terminal 13 (TC) and 4 (CG) of the
DLC3.
(7) Inspect ignition timing at idle.
Ignition timing:
10 to 18 BTDC (1ZZ±FE)
3.5 to 11.5 BTDC (3ZZ±FE)
(8) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(9) Remove the timing light.
(10) Install the cylinder head cover with the 2 nuts and
2 clips.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect the tachometer test prove to
terminal 9 (TAC) of DLC3.
SST 09843±18040
(d) Check the idle speed.
Idle speed: 600 to 700 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the ignition coil.
(c) Remove the spark plugs.
(d) Inspect cylinder compression pressure.
SST 09992±00500
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.

A77913
Turn
Push
A77914
Turn
A81621
Fuel Pipe
Clamp
Push
11±28
±
FUEL FUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply a light coat of spindle oil or gasoline on the place where a fuel delivery pipe contacts the O±ring.
(c)Push the fuel injector while twisting it back and forth to
install it to the fuel delivery pipe.
NOTICE:

Be careful not to twist the O±ring.

After installing the fuel injectors, check that they turn
smoothly. If not, reinstall it with a new O±ring.
8.INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a)Install 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head.
(b)Place the fuel delivery pipe and the 4 fuel injectors togeth- er to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c)Temporarily install 2 bolts which are used to secure the fuel delivery pipe to the cylinder head.
(d)Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
is incorrect installation of O±ring. Replace with the O±ring.
(e)Tighten the 2 bolts. Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(f)Connect the 4 fuel injector connectors.
(g)Install the 2 wire harness clamps.
(h)Connect the ventilation hose.
9.CONNECT FUEL TUBE SUB±ASSY
(a)Push in the connector to the pipe until it makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part.

After connecting, check if the connector and the pipe
are securely connected by pulling on them.
(b)Install the fuel pipe clamp.
10.INSTALL AIR CLEANER CAP SUB±ASSY
11.CHECK FOR FUEL LEAKS (See page 11±19)
12.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)

110U2±01
A77915
±
FUEL FUEL PRESSURE PULSATION DAMPER
ASSY(1AZ±FE)11±29
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PRESSURE PULSATION DAMPER ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
3.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
4.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26)
SST09268±21010
5.REMOVE FUEL PRESSURE PULSATION DAMPERASSY
(a)Remove the 2 bolts, and then remove the fuel pressure pulsation damper.
6.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY
(a)Apply a light coat of spindle oil or gasoline to a new O±ring, and instal\
l it to the fuel pressure pulsation damper.
(b)Install the fuel pressure pulsation damper with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
7.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
8. INSTALL AIR CLEANER CAP SUB±ASSY
9.CHECK FOR FUEL LEAKS (See page 11±19)
10.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)