engine coolant TOYOTA AVENSIS 2003 Service Owner's Manual

A78511
(b)
A78512
(d)
A78513
(g)
(h)
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1AZ±FSE)
10±45
AVENSIS REPAIR MANUAL (RM1018E)
(b)Remove the bolt, and then remove the ground terminal.
(c)Remove the 4 bolts, and then remove the throttle body
bracket.
(d)Disconnect the throttle motor connector.
(e)Remove the 4 bolts, and then remove the throttle body.
(f)Remove the gasket from the intake manifold.
(g)Disconnect the water by±pass hose No. 1.
(h)Disconnect the water by±pass hose No. 2.
7.INSTALL THROTTLE BODY ASSY
(a)Connect the water by±pass hose No. 2.
(b)Connect the water by±pass hose No. 1.
(c)Install a new gasket to the intake manifold.
(d)Install the throttle body with the 4 bolts. Torque: 9.0 N
m (90 kgf
cm, 80 in.
lbf)
(e)Connect the throttle motor connector.
(f)Install the throttle body bracket with the 4 bolts. Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
(g)Install the ground terminal with the bolt. Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
(h)Install the wire harness protector with the bolt. Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
8.INSTALL AIR CLEANER CAP SUB±ASSY Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
9.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
10.ADD ENGINE COOLANT (See page 16±31)
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
12. INSTALL ENGINE ROOM COVER SIDE
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100FC±01
A784575 Claws
A78458
A78459
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1ZZ±FE)
10±9
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER
(a)Remove the retainer and 4 clips.
(b)Unfasten the 5 claws and remove the radiator support
opening cover.
2.REMOVE ENGINE ROOM COVER SIDE
(a)Remove the 2 clips, and then remove the engine room cover side.
3.DRAIN ENGINE COOLANT (See page 16±7)
4. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips, and then remove the cylin- der head cover No. 2.
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A78463
A
A
A
A
BB
A
(d)
(c)
A78468
65.1 mm
(2.563 in.)
Rotation
Center of
Throttle Link
18

10±12
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the throttle body bracket with the 3 bolts and 2 nuts. (A/T)
Torque:
30 N
m (306 kgf
cm, 22 ft
lbf) for bolt and nut A
(c)Install the throttle body and the throttle body bracket with
the 5 bolts and 2 nuts. (M/T)
Torque:
30 N
m (306 kgf
cm, 22 ft
lbf) for bolt and nut A
13 N
m (133 kgf
cm, 10 ft
lbf) for bolt B
(d)Connect the ISC valve connector.
(e)Connect the throttle position sensor connector.
(f)Connect the ventilation hose.
(g)Connect the water by±pass hose No. 2.
(h)Connect the water by±pass hose.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il-
lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
16.INSTALL AIR CLEANER CAP SUB±ASSY Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
17.INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±7)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER
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100FE±01
A78497
A78498
(a)
(b)
(c)
A78499
(d)
(e)
A78500
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(3ZZ±FE)
10±15
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
3.DRAIN ENGINE COOLANT (See page 16±7)
4.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
5.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±9)
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator controlcable.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the ventilation hose.
(b) Disconnect the water by±pass hose.
(c) Disconnect the water by±pass hose No. 2.
(d) Disconnect the throttle position sensor.
(e) Disconnect the ISC valve connector.
(f) Remove the bolt and 2 nuts, and then remove the acceler- ator control bracket and the throttle body.
(g) Remove the gasket from the intake manifold.
8. REMOVE ISC VALVE
(a) Remove the 4 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.
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A78501
A78503
30
to 45

A78469
66.3 mm
(2.610 in.)
Rotation
Center of
Throttle Link
11

10±16
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE THROTTLE POSITION SENSOR
(a)Remove the 2 screws, and then remove the throttle posi- tion sensor.
10.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that the throttle valve is fully closed.
(b)With the throttle position sensor rotated 30
to 45
coun- terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
11.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 4 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
12.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the accelerator control brack- et with the bolt and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
13.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
14.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±9)
15.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
16.ADD ENGINE COOLANT (See page 16±7)
17.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
18. INSTALL ENGINE ROOM COVER SIDE
19. INSTALL RADIATOR SUPPORT OPENING COVER
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110UC±01
A79148
SST
A79143
SST
11±78
±
FUELCOMMON RAIL ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
4.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50) 5. REMOVE FUEL INLET PIPE SUB±ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the commonrail.
SST 09023±12700
(b) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and the 2 upper infection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common
rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
7. REMOVE INJECTION PIPE SUB±ASSY NO.2 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
8. REMOVE INJECTION PIPE SUB±ASSY NO.3 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
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A79149
30 cm
(11.81 in.)
SST
±
FUELCOMMON RAIL ASSY(1CD±FTV)
11±81
AVENSIS REPAIR MANUAL (RM1018E)
19.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the common rail replaced, must re-
place fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the injec-
tion pump side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
20.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
21. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
22.ADD ENGINE COOLANT(See page 16±44)
23.CHECK FOR ENGINE COOLANT LEAKS(See page 16±37)
24.CHECK FOR FUEL LEAKS(See page 11±60)
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110UA±01
A15950
±
FUELINJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
11±69
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.DRAIN ENGINE COOLANT(See page 16±44)
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
9.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
10.DISCONNECT RADIATOR HOSE OUTLET
(a)Disconnect the radiator hose outlet from the water inlet.
11.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.REMOVE INJECTOR DRIVER
(a)Remove the 2 nuts which are used to secure the injector driver.
(b)Disconnect the injector driver connector and the harness clamp.
(c)Remove the injector driver.
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
15.REMOVE CRANKSHAFT PULLEY(See page 14±307)
SST09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY
(a)Remove the bolt and washer, then remove the idler pulley.
17.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
19. REMOVE TIMING BELT GUIDE
20. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 6 bolts and the engine mounting bracket.
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
23.REMOVE TIMING BELT(See page 14±307)
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±
FUEL INJECTION OR SUPPLY PUMP ASSY (1CD±FTV)
11±75
AVENSIS REPAIR MANUAL (RM1018E)
52.INSTALL TIMING BELT GUIDE(See page 14±307)
53.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
54.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
55. INSTALL IDLER PULLEY SUB±ASSY
Torque: 40 N
m (408 kgf
cm, 30 ft
lbf)
56.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
57.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
58. INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
59. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
60.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
61. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
62.INSTALL AIR CLEANER ASSY (See page 11±60)
63. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
64.ADD ENGINE COOLANT(See page 16±44)
65.CHECK FOR ENGINE COOLANT LEAKS(See page 16±37)
66.CHECK FOR FUEL LEAKS(See page 11±60)
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1209I±02
±
EMISSION CONTROL EGR 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 s\
moke 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 m\
eter (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 andthe 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 i\
n 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.
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