check engine TOYOTA AVENSIS 2002 Owner's Manual

4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26

C62956
D30058
1CD±FTV Engine Type: Others:
Transaxle Side


D25281
AB
C62958
± CLUTCHCLUTCH UNIT (MTM)
42±27
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE CLUTCH DISC ASSY
NOTICE:
Keep the lining part of the clutch disc assy, the pressure plate and surface of the flywheel sub±assy
away from oil and foreign attachment.
9. INSPECT CLUTCH DISC ASSY
(a) Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assy as necessary.
(b) Install the clutch disc assy to the transaxle assy.
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
(c) Using a dial gage, check the clutch disc assy runout.
Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assy as necessary.
10. INSPECT CLUTCH COVER ASSY
(a) Using vernier calipers, inspect the diaphragm spring for
the depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assy as necessary.
11. INSPECT FLYWHEEL SUB±ASSY
(a) Using a dial gage, inspect the flywheel sub±assy runout.
Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub±assy as necessary.

Q01060
D30059
1CD±FTV Engine Type: Others:
Flywheel Side
SST(s)
D26323
SST(s)
Matchmarks 7
1 (Temporally), 4
3
6
2.58
D00205
SST(s)
42±28
± CLUTCHCLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
12. INSPECT CLUTCH RELEASE BEARING ASSY
(a) Turn the release bearing by hand while applying force in
the axial direction.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
Replace the release bearing assy as necessary.
13. INSTALL CLUTCH DISC ASSY
(a) Insert SST(s) in the clutch disc assy, then insert them in
the flywheel sub±assy.
SST 09301±00220
NOTICE:
Take care not to insert the clutch disc assy in the wrong
direction.
14. INSTALL CLUTCH COVER ASSY
(a) Align matchmarks on the clutch cover assy and flywheel
sub±assy.
(b) Following the procedures shown in the illustration, tighten
the 6 bolts, in the order starting from the bolt located near
the knock pin on the top.
Torque: 19 N
m (195 kgf
cm, 14 ft
lbf)
HINT:

Following the order in the illustration, tighten the bolts at
a time evenly.

Move SST(s) up and down, right and left lightly, after
checking that the disc is in the center, and then tighten the
bolts.
15. INSPECT AND ADJUST CLUTCH COVER ASSY
(a) Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non±alignment: 0.5 mm (0.020 in.)
If the alignment is not as specified, adjust the diaphragm spring
tip alignment using SST(s).
SST 09333±00013

D26819
EXCEPT 1CD±FTV Engine Type:
1CD±FTV Engine Type:
Release Hub Grease
±
CLUTCH CLUTCH UNIT (MTM)
42±29
AVENSIS REPAIR MANUAL (RM1018E)
16. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle assy.
Torque:
1ZZ±FE/3ZZ±FE/1CD±FTV Engine Type: 37 N
m (375 kgf
cm, 27 ft
lbf)
1AZ±FSE/1AZ±FE Engine Type: 47 N
m (480 kgf
cm, 35 ft
lbf)
17. INSTALL RELEASE BEARING HUB CLIP
18. INSTALL CLUTCH RELEASE FORK SUB±ASSY
(a) Apply the release hub grease to the release fork and re-lease bearing assy contact, release fork and push rod
contact, and release fork pivot points.
Sealant:
Part No. 08887±01806, RELEASE HUB GREASE or
equivalent
(b) Install the release fork to the release bearing assy.
19. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Apply the clutch spline grease to the input shaft spline. Sealant:
Part No. 08887±01706, CLUTCH SPLINE GREASE or equivalent
(b) Install the bearing to the release fork, and then install them to the tr\
ansaxle assy.
NOTICE:
After the installation, move the folk forward and backward to check that\
the release bearing slides
smoothly.
20. INSTALL CLUTCH RELEASE FORK BOOT
21. INSTALL MANUAL TRANSAXLE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 41±15)
(b)1AZ±FE, 1AZ±FSE Engine (See page 41±24)
(c)1CD±FTV Engine (See page 41±33)

69066±02
B67416
B67417
B68374
21
5
3
± COMMUNICATION SYSTEMHORN SYSTEM
69±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT LOW PITCHED HORN ASSY
(a) Check operation of the horn.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+) Terminal 1
Battery positive (±) Horn bodyHorn sounds
If the result is not as specified, replace the horn assy.
2. INSPECT HIGH PITCHED HORN ASSY
(a) Check operation of the horn.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+) Terminal 1
Battery positive (±) Horn bodyHorn sounds
If the result is not as specified, replace the horn assy.
3. INSPECT HORN RELAY ASSY
(a) Remove the HORN relay from the engine room R/B No.
2.
(b) Check the horn relay resistance.
Standard:
Tester ConnectionSpecified Condition
10 k
or higher
3 ± 5Below 1

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

1600R±13
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
16±17
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 77
C (171
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolant temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 95.5
C (204
F))
(a) Start the engine, and raise coolant temperature to above 95.5
C (204
F).
HINT:
Coolant temperature is the detected value by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.

1600R±12
± COOLINGCOOLING FAN SYSTEM (1AZ±FSE)
16±29
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolant temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 100
C (212
F))
(a) Start the engine, and raise coolant temperature to above 100
C (212
F).
HINT:
Coolant temperature is the detected value by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.

1606N±03
A57065
21


± COOLINGCOOLING FAN SYSTEM (1CD±FTV)
16±41
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
(c) Disconnect the temperature detect switch connector.
(d) Connect the terminals on the temperature detect switch connector.
(e) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay and cooling fan, and check for a open circuit between the cooling
fan relay and temperature detect switch.
(f) Reconnect the temperature detect switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 93
C (199
F))
(a) Start the engine, and raise coolant temperature to above 93
C (199
F)
HINT:
Coolant temperature is the detected value by the temperature detect switch on the radiator lower tank.
(b) Check that the cooling fan rotates.
If not, replace the temperature detect switch.
3. INSPECT COOLING FANS
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-
tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
Approx. 13.2 A at 20
C (68
F)
(d) Reconnect the cooling fan connector.

1600R±14
± COOLINGCOOLING FAN SYSTEM (1ZZ±FE/3ZZ±FE)
16±5
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 94.5
C (202
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check if there is its connector
disconnection or circuit open between them.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for short in a circuit between the
cooling fan relay and the engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 96
C (205
F))
(a) Start the engine, and raise coolant temperature to above 96
C (205
F).
HINT:
Coolant temperature is detected by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage: Approximately. 8 to 12 A at 20
C (68
F)
(d) Reconnect the cooling fan connector.

A79301
Upper Hook
Fan
Shroud
Radiator
16±12
±
COOLING RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
10.INSTALL RADIATOR ASSY
(a)Align the 2 keyways of the fan shroud with the 2 keys lo- cated on the lower bottom of the radiator and fit them.
(b)Install the fan should to the radiator with the 2 upper hooks. You can hear ºclickº sounds when the hooks are
securely fitted.
(c)Install the 2 support radiator LWRs to the radiator.
(d)Install the radiator with the 2 bolts and 2 radiator support
uppers.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(e)Install the relay block with the 2 bolts.
(f)Connect the fan connector and 2 harness clamps.
11.ADD ENGINE COOLANT (See page 16±7)
12.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)