stop start TOYOTA AVENSIS 2002 Repair Manual

3201G±07
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
G24221
Ventilation No Ventilation
± BRAKEBRAKE BOOSTER ASSY (LHD)
32±17
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (LHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.

320GN±02
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
G24221
Ventilation No Ventilation
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±21
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (RHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.

CL0102Pedal Free Play
CL0512
25 mm (0.98 in.) or more
Release Point
Full Stroke
End Position
± CLUTCHCLUTCH PEDAL SUB±ASSY (MTM)
42±3
AVENSIS REPAIR MANUAL (RM1018E)
(e) Adjust the pedal free play and push rod play.
(1) Loosen the lock nut and turn the push rod until the
free play and push rod play are correct.
(2) Tighten the lock nut.
(3) After adjusting the pedal free play, check the pedal
height.
(4) Connect the air duct and install the lower finish pan-
el.
(f) Check the clutch release point.
(1) Pull the parking brake lever and install wheel stop-
per.
(2) Start the engine and idle.
(3) Without depressing the clutch pedal, slowly adjust
the shift lever to the reverse position until the gears
contact.
(4) Gradually depress the clutch pedal and measure
the stroke distance from the point that the gear
noise stops (release point) up to the full stroke end
position.
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-
tions.

Check pedal height.

Check push rod play and pedal free play.

Bleed the clutch line.

Check the clutch cover assy and disc 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.

1209I±02
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
12±17
AVENSIS REPAIR MANUAL (RM1018E)
EGR SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
HINT:
In a malfunction where the EGR system is always on, black smoke or white smoke may be emitted from the
exhaust pipe. If this occurs, inspect the EGR system as well.
1. INSPECT SEATING OF EGR VALVE
(a) Start the engine and check that it starts and runs at idle.
2. INSPECT HOT ENGINE CONDITION (WHEN USING HAND±HELD TESTER)
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Refer to the hand±held tester operator's manual for further details.
(d) Warm up the engine, the coolant temperature should be above 75
C (109
F) and bellow 90
C
(194
F).
(e) Check that the AFM reading is 5
ega
8 g/s with the engine idling.
(f) Operate the EGR valve with a hand±held tester. Regulate the valve opening angle to 0, and check that
the AFM reading is 11
ega
17 g/s..
If the AFM reading is out of range in either (e) or (f), replace the EGR valve.
If the AFM is out of range in both (e) and (f), replace the air flow meter (air cleaner) and check the EGR valve
operation again.
3. INSPECT HOT ENGINE CONDITION (WHEN NOT USING HAND±HELD TESTER)
(a) Install the vacuum gauge.
(1) Using a 3±way connector, connect a vacuum gauge to the hose between the intake manifold and
the turbo pressure sensor.
(b) Warm up the engine, the coolant temperature should be above 75
C (109
F) and bellow 90
C
(194
F).
(c) Check that the vacuum gauge indicates about more than 2.5 kPa (19 mmHg 0.7 in Hg).
(d) Stop the engine (IG OFF), remove the EGR valve connector, restart the engine, and check that load
under idling is less than 2.5 kPa (19 mmHg 0.7 in Hg).
If the load pressure exceeds the above value, replace the EGR valve.

1209E±02
A65749
E1
OX2BOX1B
ECM
A77114
12±6
± EMISSION CONTROLEMISSION CONTROL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT AIR±FUEL RATIO COMPENSATION SYS-
TEM
HINT:
You can also check the system by choosing ºDATA MONITOR/
O
2 SENSOR OUTPUT VOLTAGEº on the monitor of the hand±
held tester.
(a) Connect the hand±held tester to terminals 21 (OX1B) and
7 (E1) and to terminals 29 (OX2B) and 7 (E1) of the ECM.
CAUTION:
Connect test leads from the back side of the connector with
the ECM connected.
(b) Warm up the heated oxygen sensor with the engine
speed at 2,500 rpm for approximately 2 minutes.
(c) Confirm that the voltage output varies between 0V to 1V
with the engine speed at 2,500 rpm.
OK:
The voltage output varies more than 8 times in 10 se-
conds.
CAUTION:

Perform the check immediately after the warming up.

If the voltage variation could not be verified, warm up
the heated oxygen sensor again.
2. INSPECT FUEL CUT OFF RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating sounds.
(c) Check that injector operating sounds stops momentarily and then resumes when the throttle lever is
released.
3. INSPECT EVAPORATIVE EMISSION CONTROL SYS-
TEM
(a) After starting the engine, disconnect the vacuum hose
shown in the illustration.
(b) Check if vacuum occurs at the VSV port when choosing
ºACTIVE TESTº and ºPURGE VSVº according to the dis-
play on hand±held tester.
(c) Finish ºACTIVE TESTº, then reconnect the vacuum hose.
(d) After entering to ºECU DATA MONITORº on the hand±
held tester, choose ºPURGE VSVº to check the operation
of the purge VSV.
(e) After driving the vehicle with a warm engine, confirm that
the VSV turns from off to on.

1209G±02
A59588
E1
OX1AOX1B
OX2B OX2A
ECM
A77114
± EMISSION CONTROLEMISSION CONTROL SYSTEM (1AZ±FSE)
12±11
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
1. INSPECT AIR±FUEL RATIO COMPENSATION SYS-
TEM
HINT:
You can also check the system by choosing ºDATA MONITOR/
O
2 SENSOR OUTPUT VOLTAGEº on the monitor of the hand±
held tester.
(a) Connect the hand±held tester to the following each pair
of the ECM terminals:
(1) Terminals 21 (OX1B) and 1 (E1)
(2) Terminals 22 (OX1A) and 1 (E1)
(3) Terminals 23 (OX2A) and 1 (E1)
(4) Terminals 29 (OX2B) and 1 (E1)
CAUTION:
Connect test leads from the back side of the connector with
the ECU connected.
(b) Warm up the heated oxygen sensor with the engine
speed at 2,500 rpm for approximately 2 minutes.
(c) Confirm that the voltage output varies between 0V to 1V
with the engine speed at 2,500 rpm.
OK:
The voltage output varies more than 8 times in 10 se-
conds.
CAUTION:

Perform the check immediately after the warming up.

If the voltage variation could not be verified, warm up
the heated oxygen sensor again.
2. INSPECT FUEL CUT OFF RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating sounds.
(c) Check that the injector operating sounds stops momentarily and then resumes that when the throttle
lever is released.
3. INSPECT EVAPORATIVE EMISSION CONTROL SYS-
TEM
(a) After starting the engine, disconnect the vacuum hose
shown in the illustration.
(b) Check if vacuum occurs at the VSV port when choosing
ºACTIVE TESTº and ºPURGE VSVº according to the dis-
play on hand±held tester.
(c) Finish ºACTIVE TESTº, then reconnect the vacuum hose.
(d) After entering to ºECU DATA MONITORº on the hand±
held tester, choose ºPURGE VSVº to check the operation
of the purge VSV.
(e) After driving the vehicle with a warm engine, confirm that
the VSV turns from off on to.