manual transmission TOYOTA AVENSIS 2002 Repair Manual

16±20
±
COOLING ENGINE COOLANT(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35 C (±31 F)) or 60 %
(freezing protection down to ±50 C (±58 F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times with hard.

If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:

If the level gets lower, perform the procedures above again.

If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)

16±32
±
COOLING ENGINE COOLANT(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
2.ADD ENGINE COOLANT
(a)Tighten the radiator drain plug, and pour coolant into radiator until it \
overflows. Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD6.0 (6.3, 5.3)
M/TRHD6.1 (6.4, 5.4)
A/TLHD6.3 (6.7, 5.5)
A/TRHD6.4 (6.8, 5.6)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized wat\
er or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water ac\
cording to the manufactur-
er's directions.

Using of coolant with includes more than 50 % (freezing protection down to ±\
35 C (±31 F)) or 60 %
(freezing protection down to ±50 C (±58 F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times with hard.

If the coolant level gets lower, pour coolant.
(b)Reinstall the radiator cap.
(c)Pour engine coolant into the reservoir tank until it reaches full line.
(d)Warm up the engine until the thermostat valve begins to open.
HINT:
Press the radiator inlet and outlet hose several times with hard during \
the warming up.
(e)Stop the engine and wait until the coolant temp. Gets cold. Then remove the radiator cap to check the coolant level.
HINT:

If the level gets lower, perform the procedures above again.

If the level does not gets lower, adjust the reservoir tank coolant level.
3.CHECK FOR ENGINE COOLANT LEAKS(See page 16±25)

160MH±01
A64364
Radiator CapCylinder Block
Drain Cock Plug
Drain Pipe
Radiator
Drain Cock Plug
± COOLINGENGINE COOLANT (1ZZ±FE/3ZZ±FE)
16±7
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE COOLANT (1ZZ±FE/3ZZ±FE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(a) Remove the radiator cap.
(b) Loosen the radiator drain cock plug and the cylinder block
drain cock plug, and drain engine coolant.
(c) Close the radiator drain cock plug.
(d) Close the cylinder block drain plug.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf) for engine
2. ADD ENGINE COOLANT
(a) Tighten the radiator drain plug, and pour coolant into radiator until it overflows.
Capacity:
Transmission typeSteeringCoolant Capacity
[liters (US gts, lmp. gts)]
M/TLHD5.8 (6.1, 5.1)
M/TRHD5.9 (6.2, 5.2)
A/TLHD5.7 (6.0, 5.0)
A/TRHD5.8 (6.1, 5.1)
NOTICE:

Do not use an alcohol type coolant or plain water alone.

The coolant should be mixed with plain water (preferably demineralized water or distilled wa-
ter).
HINT:

Use of improper coolants may damage engine cooling system.

Use ºToyota Long Life Coolantº or equivalent and mix it with plain water according to the manufactur-
er's instruction.

Using of coolant with includes more than 50 % (freezing protection down to ±35C (±31F)) or 60 %
(freezing protection down to ±50C (±58F)) of ethylene±glycol is recommended but not more than
70 %.

Press the radiator inlet and outlet hose several times by hand.

If the coolant level gets lower, pour coolant.
(b) Reinstall the radiator cap.
(c) Pour engine coolant into the reservoir tank until it reaches full line.

±
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).

A53763
E2PSW
10±38
±
ENGINE CONTROL SYSTEM SFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
2.INSPECT POWER STEERING OIL PRESSURE SEN- SOR
(a)Using a voltmeter, measure the voltage between termi-
nals PSW and E2.
Voltage:
ConditionVoltage (V)
Not spin the steering wheel at engine idling9 to 14
Spin the steering wheel at engine idling0 to 3
3.INSPECT THROTTLE BODY
(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±39), 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±39), wiring
and ECM.
If you have no hand±held tester, measure voltage between terminals (VTA1 ± E2, VTA2 ± E2) of the ECM
connector (See page 05±318).
(c) Inspect the air assist system.
(1) Start the engine and check that the CHK ENG 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): 700
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.
4. 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 (VPA ± EPA, VPA2 ± EPA2) of the ECM
connector (See page 05±318).

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.

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
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.

A77314
A/T:
Clip
Transmission
Control Cable Assy
N´m (kgf´cm, ft´lbf)
: Specified torque
M/T:
Transmission Control
Cable Assy
5.0 (51, 44 in.
lbf)
12 (120, 9.0)
M/T:
Clutch Release
Cylinder Assy
12 (122, 8.9)
Clip
5.0 (51, 44 in.
lbf)
9.0 (92, 80 in.
lbf)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FE)
14±115
AVENSIS REPAIR MANUAL (RM1018E)

A77298
LHD Steering Position typeRHD Steering Position type
14±124
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE FRONT AXLE HUB RH NUT SST09330±00030
HINT:
Perform the same procedure as above on the opposite side.
41.SEPARATE TIE ROD END SUB±ASSY LH (See page 51±36)
42.SEPARATE TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
43.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 26±26)
44.SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
45.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
(See page 26±21)
46.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) (See page 26±16)
47.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
48.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE)
HINT:
Perform the same procedure as above on the opposite side.
49.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
50.SEPARATE FRONT AXLE ASSY RH (See page 30±6)
HINT:
Perform the same procedure as above on the opposite side. 51.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/TTRANSAXLE)
(a)Remove 7 bolts as shown in the illustration.
52.SEPARATE TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
53.SEPARATE TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)
54. SEPARATE ACCELERATOR CONTROL CABLE ASSY