fuel pressure TOYOTA AVENSIS 2003 Service Workshop Manual

010BJ±01
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TERMS (1ZZ±FE/3ZZ±FE)
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector
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01±8
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E) Abbreviations Meaning
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECTElectronic Control Transmission
ECUElectronic Control Unit
EDElectro±Deposited Coating
EDUElectronic Driving Unit
EDICElectric Diesel Injection Control
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
EGR±VMEGR±Vacuum Modulator
ELREmergency Locking Retractor
ENGEngine
ESAElectronic Spark Advance
ETCSElectronic Throttle Control System
EVAPEvaporative Emission Control
EVPEvaporator
E±VRVElectric Vacuum Regulating Valve
EXExhaust
FEFuel Economy
FFFront±Engine Front±Wheel±Drive
F/GFuel Gauge
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FRFront
F/WFlywheel
FW/DFlywheel Damper
FWDFront±Wheel±Drive
GASGasoline
GNDGround
HACHigh Altitude Compensator
H/BHatchback
H±FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
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010BK±01
01±12
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±13
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
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17045±03
A56466
Recommended Viscosity (SAE)
BEFORE NEXT OIL CHANGE TEMPERATURE RANGE ANTICiPATED416 2738
0 20 40 60 80 100
±29
±20 ±18 ±7

C

F 20 W ± 50
15 W ± 40
10 W ± 30
5 W ± 30 PREFERRED
B14332
Oil Pressure Switch
B14333
Oil Pressure Gauge
17±20
±
LUBRICATION LUBRICATION SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
LUBRICATION SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. CHECK ENGINE OIL LEVEL
(a) After warm up the engine and then 5 minutes after the engine stop, oil l\
evel should be between the low level and full level marks of the dipstick.
If low, check for leakage and add oil up to the full level mark.
NOTICE:
Do not fill with engine oil above the full level mark.
2. CHECK ENGINE OIL QUALITY
(a) Check the oil for deterioration, entry of water, discoloringor thinning.
If the quality is visibly poor, replace the oil. Oil grade:
Use ACEA B1, API grade CF ± 4 or CF
(You may also use API CE or CD)
SAE 5W ± 30 is the best choice for your vehicle, for
good fuel economy, and good starting in cold weath-
er.
3. REMOVE OIL PRESSURE SWITCH ASSY
(a) Disconnect the oil pressure switch connector.
(b) Using a deep socket wrench 24mm, remove the oil pres- sure switch.
4. INSTALL OIL PRESSURE GAUGE
(a) Install the oil pressure gauge.
5. WARM UP ENGINE
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170FU±01
A77281
17±8
±
LUBRICATIONOIL PUMP ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil. Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
10.REMOVE GENERATOR ASSY (See page 19±20)
11.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
12.SEPARATE VANE PUMP ASSY (See page 14±139)
13.SEPARATE RETURN TUBE SUB±ASSY (See page 14±139)
14. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE) (See page 14±139)
15. SEPARATE VANE PUMP OIL RESERVOIR ASSY
16.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±139)
17. SEPARATE ENGINE WIRE
18. REMOVE ENGINE SERVICE COVER BRACKET RH (W/O AIR CONDITIONING)
(a) Remove a bolt and the engine service cover bracket RH.
19.REMOVE COOLER BRACKET (LHD(W/ AIR CONDITIONER) STEERING POSITION TYPE\
) (See
page 14±139)
20. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
21. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
22.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±139)
23.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±139)
24.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±139)
25.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±139)
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170FX±01
A77339
±
LUBRICATIONOIL PUMP ASSY(1AZ±FSE)
17±15
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1AZ±FSE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE FRONT WHEEL RH
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN ENGINE OIL
(a)Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm,18 ft
lbf)
8.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the engine cover No. 1.
9.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
10.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±33)
11.SEPARATE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
12.REMOVE FUEL PUMP ASSY (See page 11±52)
13.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
14.REMOVE GENERATOR ASSY (See page 19±20)
15.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
16.SEPARATE VANE PUMP ASSY (See page 14±222)
17.SEPARATE RETURN TUBE SUB±ASSY (See page 14±222)
18. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14±222)
19. SEPARATE VANE PUMP OIL RESERVOIR ASSY
20.REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14±222)
21. SEPARATE ENGINE WIRE
22.REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14±222)
23. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(a) Remove a bolt and the engine service cover bracket RH.
24. REMOVE IGNITION COIL ASSY
(a) Remove 4 bolts and the ignition coils.
25.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
26.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±222)
27.REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14±222)
28.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14±222)
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17±18
±
LUBRICATIONOIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
64.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
65.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
66.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
67.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
68.INSTALL VANE PUMP ASSY Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
69.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
70.INSTALL GENERATOR ASSY (See page 19±20)
71.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
72.INSTALL FUEL PUMP ASSY (See page 11±52)
73.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
74.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
75.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
76. ADD ENGINE OIL
77. CHECK FOR ENGINE OIL LEAKS
78. CHECK FUEL LEAK
79. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
80. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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5507E±03
AC2810
AC2811
N11084
Wrong Okay
HI
LO
HILO
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
55±1
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cold water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a hospital or see a physician for profes- sional treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system, oil lu-
brication will be insufficient and compressor may burnout may
occur, so take care to avoid this, necessary care should be tak-
en.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING
Open and close the only low pressure valve. If the high pressure
valves are opened, refrigerant flows in the reverse direction and
cause the charging cylinder to rupture.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating, etc.
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650SV±01
I33423
V LH LineV RH LineV Line
Ground
H Line
±
LIGHTING HEADLAMP UNIT LH
65±19
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. HEADLIGHT AIM ONLY
HINT:

Perform aiming adjustment with Low±beam.

Since the Low±beam light and the High±beam light is a
unit, if aiming on either side is connect, the other side
should also be connect.
However, check both beams just to make sure.
(a) Prepare vehicle in the following conditions.

Check that any damage or deformation does not exist on
the body around the headlights.

Fuel tank is full.

The tire inflation pressure is at the specified level.

Vehicle is parked at a level surface.

A person having an average weight sits in the driver's
seat.

Vehicle is bounced up and down to stabilize the suspen-
sion to the normal position.
(b) Prepare a thick white paper (Draw base lines).
HINT:

Stand the paper perpendicular as against a wall.

The base lines differ for ºLow±beam inspectionº and
ºHigh±beam inspectionº.
(1) V line (Vehicle Center position) Draw a vertical line down the center of the paper in
order to align it with the center of the vehicle.
(2) H line (Headlight height)
Draw horizontal line across the paper at the same
height from the ground as the center mark for the
Low±beam lights.
(3) V LH line, V RH line (Center mark position of right and left headlights)
Draw vertical lines, for left & right, at the same posi-
tion as the center mark for the Low±beam lights.
HINT:
Follow the same procedures when adjusting the High±beam
lights.
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