engine code TOYOTA AVENSIS 2003 Service User Guide

01±38
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E) Abbreviations Meaning
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Camshaft
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
DVDDigital Versatile Disc
EBDElectric Brake Force Distribution
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
EMPSElectric Motor Power Steering
ENGEngine
ESAElectronic Spark Advance
ETCS±iElectronic Throttle Control System±intelligent
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
GPSGlobal Positioning System
HACHigh Altitude Compensator
H/BHatchback
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010BA±14
01±42
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E)
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/INJ)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble 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 IgnitionDistributorless Ignition (DLI)
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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100FR±01
A79186
±
ENGINE CONTROL SYSTEMECM
10±65
AVENSIS REPAIR MANUAL (RM1018E)
ECM
REPLACEMENT
HINT:
1CD±FTV Engine Type:
Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes
which are used to optimize fuel injection for the injectors. When replacing t\
he ECM, the compensation codes
must be set to the new ECM.
1.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
2.REMOVE ECM
(a)Disconnect the 4 ECM connectors (1ZZ±FE, 3ZZ±FE,1AZ±FE, 1CD±FTV).
(b)Disconnect the 5 ECM connectors (1AZ±FSE).
(c)Disconnect the wire harness clamp.
(d)Remove the bolt and screw, then remove the ECM.
(e)Remove the 2 screws and the ECM bracket No. 1 from the ECM.
(f)Remove the 2 screws and the ECM bracket No. 2 from the ECM.
3.INSTALL ECM Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
4.INSTALL GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
5.REGISTRATION OF INJECTOR COMPENSATION CODE (1CD±FTV ENGINE TYPE) (See page 05±528)
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110U8±01
A79143
SST
11±60
±
FUELINJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes
which are used to optimize fuel injection for the injectors. When replacing t\
he injector assembly, a compensa-
tion code for the new injector assembly must be set to the ECM.
1.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
4.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
5.REMOVE AIR TUBE NO.1 (See page 14±270) 6. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clampsfrom 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.
9. REMOVE INJECTION PIPE SUB±ASSY NO.4 SST 09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10. REMOVE TIMING BELT NO.2 COVER
(a) Remove the 7 bolts and 7 seal washers, then remove the timing belt cover\
.
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A62811
Cord Mark
A62812
Upper Side Rail
Front Compression No. 2
Lower Side Rail
Compression No. 1
or Expander
A01188
A01190
A01189
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
14±51
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
34. INSTALL PISTON RING SET
HINT:
In case of reusing the piston rings, install them to the matched
pistons with the surfaces faced correctly.
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark (No.2 only): T or 2R
(c) Position the piston rings so that the ring ends are as shown.
35. INSTALL CONNECTING ROD BEARING
(a) Align the bearing claw with the groove of the connecting rod or connecting cap.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the connecting rod and let not stick the oils and fats.
36. INSTALL CRANKSHAFT
(a) Install the upper bearing with an oil groove on cylinder block.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.
(b) Install the lower bearing on the bearing cap sub±assy.
NOTICE:
Clean the backside of the bearing and the bearing surface
of the bearing cap and let not stick the oils and fats.
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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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AVENSIS (EWD526E)5
B
[A]
: System Title
[B] : Indicates a Relay Block. No shading is used and
only the Relay Block No. is shown to distinguish it
from the J/B
Example: Indicates Relay Block No.1
[C] : ( ) is used to indicate different wiring and
connector, etc. when the vehicle model, engine
type, or specification is different.
[D] : Indicates related system.
[E] : Indicates the wiring harness and wiring harness
connector. The wiring harness with male terminal is
shown with arrows (
).
Outside numerals are pin numbers.
Female Male ( )
The first letter of the code for each wiring harness
and wiring harness connector(s) indicates the
component’s location, e.g, ”E” for the Engine
Compartment, ”I” for the Instrument Panel and
Surrounding area, and ”B” for the Body and
Surrounding area.
When more than one code has the first and second
letters in common, followed by numbers (e.g, IH1,
IH2), this indicates the same type of wiring harness
and wiring harness connector.
[F] : Represents a part (all parts are shown in sky blue).
The code is the same as the code used in parts
position.
[G] : Junction Block (The number in the circle is the J/B
No. and the connector code is shown beside it).
Junction Blocks are shaded to clearly separate
them from other parts.
3C indicates that
it is inside
Junction Block
No.3
Example:
[H] : Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black W = White BR = Brown
L = Blue V = Violet SB = Sky Blue
R = Red G = Green LG = Light Green
P = Pink Y = Yellow GR = Gray
O = Orange
The first letter indicates the basic wire color and the
second letter indicates the color of the stripe.
Example: L – Y
L
(Blue) Y
(Yellow)
[I] : Indicates a wiring Splice Point (Codes are ”E” for the
Engine Room, ”I” for the Instrument Panel, and ”B”
for the Body).
The Location of splice Point I 5 is indicated by the
shaded section.
[J] : Indicates a shielded cable.
[K]: Indicates the pin number of the connector.
The numbering system is different for female and
male connectors.
Example: Numbered in order
from upper left to
lower right Numbered in order
from upper right to
lower left
Female Male
[L]: Indicates a ground point.
The first letter of the code for each ground point(s)
indicates the component’s location, e.g, ”E” for the
Engine Compartment, ”I” for the Instrument Panel
and Surrounding area, and ”B” for the Body and
Surrounding area.
[M] : Page No.
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188AVENSIS (EWD526E)
Engine Immobiliser System
GND
7
6
EFIO
GR W
EFII
7
4 CTY
T 8
8
B–W
IG
21
14
+B
W–R
VC5
KSW
10
( RHD )
GND
IND
3
8
Y–B
8
11
Y–G
CODE
13
Transponder Key Computer
TXCT
L–R
12
GR–R
AGND
9
D
I12Transponder Key Amplifier
1VC5
CODE
4
5
TXCT
1
(
LHD )
( RHD )
1(
LHD )
( RHD )
A
W–B
(
LHD )
W–B
A
W–B
W–B
( LHD )
W–B
( RHD ) 7. 5A
ECU–B 1
From Power Source System
(
See Page 120 )
6
10A
IGN
DA
4
IP
CA
6
CH
9 CI
5 DA
6
DA
8
1
2
BF
AD
Junction
ConnectorJ2 2 (
A )
, J23 (
B )
Y
YY Y
W–B
CF
13
Unlock Warning
SWU 1
W–B
( RHD )
(
LHD )(
LHD)(
LHD)
29 30 26 27
(∗ 2 )
(
∗ 1 )
IMI
IMO
Engine and ECT ECU (
A/T )
E10
Engine ECU (
M/T )
BD
AB
Junction
ConnectorJ1 0
(
A )
, J11 (
B )
RR
CK
4
(
RHD )
CA
1
RR
11 IC2
14 IM1 9
Door Courtesy SW
Front RHD10Door Courtesy SW
Front LHD 9
R
( LHD )
R (
LHD )(
LHD)
BG(
RHD )
AG
(
LHD )
AG (
LHD )
BG (
RHD )
SIL
7
W–G
W–G Junction
Connector
J 8
(
A )
, J26 (
B )
DLC3D 5
Security Indicator LightF19
1
2
B
∗
1 : Gasoline
∗ 2 : 1CD–FTV
(
RHD )
(
RHD )
( RHD )
(
RHD )
IMB
E
Junction
Connector
J1 6
W–B
A
IL : LHD ∗2, RHD
IO : LHD ∗ 1
A
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544AVENSIS (EWD526E)
J POWER SOURCE (Current Flow Chart)
4
Code or Location
Parts
Electrical Source
7.5A DRL Starter S1
Location
Example
The chart below shows the route by which current flows from the battery \
to each electrical source
(Fusible Link, Circuit Breaker, Fuse, etc.) and other Parts.
Battery
I13
25A PWR HTR 30A H-LP CLN
50A VSC (*7)
25A VSC (*7)
(*1)
(*1) (*1)
(*1)
(*1)(*2)
(*1) (*2)
(*2)
(*2)
(*1) (*2) 40A ABS (*8)
25A ABS (*8)
50A AM1 NO.1
50A AM1 NO.1
80A GLOW
50A HTR1
50A HTR2
40A HTR
30A RDI (*5)
40A RDI (*2, *6)
30A CDS
50A VSC (*2 *7)
25A VSC (*2 *7)
40A ABS (*2 *8)
25A ABS (*2 *8)
30A H/CLN (*2)
30A RR DEF
EFI Relay
(Point Side)
Ignition SW
(AM2)
H-LP Relay
(Point Side)
7.5A ECU-B 2
7.5A DOME
15A RAD NO.2
20A A/F
10A THROTTLE
15A HORN
10A HAZARD
7.5A ALT-S
15A IG2
25A F-HTR
30A RR DEF
50A EMPS 120A ALT (*5)
100A ALT (*6)
FL MAIN 3.0W 140A ALT
20A EFI
30A AM2
40A MAIN
30A DCC1
4
3
1
1
1
1
4
4
1
3
1
1
4
2
6
AVENSIS (EWD526E)
545J
R9
I13
30A PWR SEAT
10A FUEL OPN
7.5A ECU-B 1
20A D-FR P/W
20A D-RR P/W
20A P-FR P/W
20A P-RR P/W
20A FR DIC
FR DEICER Relay
10A MIR HTR
15A CIG
7.5A RAD NO.1
10A GAUGE1
7.5A GAUGE2
25A WIP
20A RR WIP
10A HTR
7.5A ECU-IG
30A PWR SEAT
7.5A RR FOG
20A S/ROOF
15A STOP
15A P/POINT
15A FR FOG
7.5A OBD2
25A DOOR
* 1:Gasoline
* 2:1CD-FTV
* 3:w/ Daytime Running Light
* 4:w/o Daytime Running Light
* 5:1AZ-FSE, 1AZ-FE
* 6:1ZZ-FE, 3ZZ-FE
* 7:w/ VSC
* 8:w/o VSC
Ignition SW (Point Side)
(AM1)
20A S-HTR
10A TAIL
7.5A PANEL
25A AM1
SEAT HTR Relay
IG1 Relay
TAIL Relay (Point Side)
(Point Side)
(Point Side)
Rear Window
Defogger Relay
10A EFI NO.1
DIM Relay
(Point Side) 10A H-LP HI RH 10A H-LP HI LH 15A H-LP RH 15A H-LP LH 7.5A ST
10A IGN 7.5A DEF I/UP
7.5A EFI NO.2
(*1)
(*2)
(*1)
(*3)
(*4)
(*3)
(*1)
6
6
7
7
7
7
7
7
7
7
7
4
22
2
6
6
65
7
1: Engine Room R/B No.1 (See Page 24 (*1) or 25 (*2))
2: Engine Room R/B No.2 (See Page 26)
3: Engine Room R/B No.3 (See Page 26)
4: Engine Room R/B No.4 (See Page 27)
5: Driver Side R/B (See Page 28)
6: Fuse Block (See Page 29)
7: Driver Side J/B (See Page 30)
[LOCATION]
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