ground TOYOTA AVENSIS 2003 Service User Guide

Z17008
CSHORT
1
2 B
1
2 1
2
A
Fig. 5
Z17009
Fig. 6
Sensor
C BA
ECU
1
2 1
2 2
1
Z17808
Fig. 7
Sensor B2
A
11 1
CB1
1ECU
2 22 2
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±35
AVENSIS REPAIR MANUAL (RM1018E)
3. CHECK SHORT CIRCUIT
(a) If the wire harness is ground shorted as shown in Fig. 5,
locate the section by conducting a continuity check with
the body ground in step (b).
(b) Check the continuity with the body ground. (1) Disconnect connectors A and C and measure the
resistance between terminals 1 and 2 of connector
A and the body ground.
Resistance: 10 k
or higher
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
In the case of Fig. 6:
Between terminal 1 of connector A and body
ground Continuity (short)
Between terminal 2 of connector A and body
ground No continuity
Therefore, the cause is a short circuit between ter-
minal 1 of connector A and terminal 1 of connector
C.
(2) Disconnect connector B and measure the resis- tance between terminal 1 of connector A and the
body ground, and terminal 1 of connector B2 and
the body ground.
In the case of Fig. 7:
Between terminal 1 of connector A and body
ground No continuity
Between terminal 1 of connector B2 and body
ground Continuity (short)
Therefore, the cause is a short circuit between ter-
minal 1 of connector B2 and terminal 1 of connector
C.
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IN0383
ExampleGround
IN0384
Ground
ECU Side
W/H Side
Ground
01±36±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
4. CHECK AND REPLACE ECU
NOTICE:

Start an inspection of the connector from the back-
side of the connector on the wire harness side with
the connector connected to the ECU.

When no measurement condition is specified, per-
form the inspection with the engine stopped and also
the ignition switch ON.
(a) First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. In this case, re-
place the ECU with one that functions normally and check
if the symptoms appear.
(1) Measure the resistance between the ECU groundterminal and body ground.
Resistance: 1
or less
(2) Disconnect the ECU connector, check the ground terminals on the ECU side and wire harness side for
bends and check the contact pressure.
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Detection Item
Indicates the system or details of the
problem. Trouble Area
Indicates the suspect areas of
the problem.
Detection Item
DTC No.
(See page)
Trouble Area
SRS

Steering wheel pad (squib)

Spiral cable

Airbag sensor assembly

Wire harness
B0103/12
(05±132) B0102/11
(05±128)
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit for that code liste\
d in the table
below (Proceed to the page given for that circuit).

Short in D squib circuit

Open in D squib circuit
B0101/14
(05±124)

Short in D squib circuit (to ground)

Short in D squib circuit (to B+)
Warning Light
ON
ON
ON
ON

Steering wheel pad (squib)

Spiral cable

Airbag sensor assembly

Wire harness

Steering wheel pad (squib)

Spiral cable

Airbag sensor assembly

Wire harness

Steering wheel pad (squib)

Spiral cable

Airbag sensor assembly

Wire harness
B0105/53
(05±136) ON

Airbag sensor assembly

Wire harness
B0106/54
Open in P squib circuit

Airbag sensor assembly

Wire harness

Short in P squib circuit (to Ground) ON
ON
B0100/13
(05±119)

Short in P squib circuit
Front passenger airbag assembly (squib)

Airbag sensor assembly

Wire harness

Front passenger airbag assembly (squib)

Front passenger airbag assembly (squib)
Page or Instructions
Indicates the page where the inspection proce-
dures for each circuit is to be found, or gives
instructions for checking and repairs.


DTC No.
Indicates the diagnostic trouble code.



±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±29
AVENSIS REPAIR MANUAL (RM1018E)
DIAGNOSTIC TROUBLE CODE CHART
The inspection procedures are shown in the table below. This table allows efficient and accurate trouble-
shooting using the diagnostic trouble codes displayed in the diagnostic trouble code chart. Proceed with
troubleshooting in accordance with the inspection procedures listed in the diagnostic c\
hart corresponding
to the diagnostic trouble codes displayed. The diagnostic trouble code chart for the Supplemental Restraint
System is shown below as an example.
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SFISFISFISFISFISFI
D25842

Circuit Description
The major role and, operation of the circuit
and its component parts are explained.

Diagnostic Trouble Code No. and Detection Item
Indicates the diagnostic trouble codes, diagnostic
trouble code settings and suspect areas for a
problem.
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
Inspection Procedures
Use the inspection procedures to determine
if the circuit is normal or abnormal. If it is ab-
normal, use it to determine whether the prob-
lem is located in the sensors, actuators, wire
harness or ECU.

Indicates the condition of the connector of the ECU
during the check.


Connections of tester are
indicated by (+), (±) after
terminals name.
Connector being checked
is connected.Connector being checked
is disconnected.
For inspection of connector
with body ground, there is
nothing about the body
ground written down.
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±31
AVENSIS REPAIR MANUAL (RM1018E)
CIRCUIT INSPECTION
How to read and use each page is shown below.
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D01556
WRONG
D01563
01±16
±
INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(±) terminal cable is disconnected. If necessary, be
sure to initialize the system.
(b) HANDLING OF ELECTRONIC PARTS (1) Do not open the cover or case of the ECU unlessabsolutely necessary (If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity).
(2) To disconnect electronic connectors, pull the con- nector itself, not the wires.
(3) Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the electronic components, air filter and emission±re-
lated components from water.
(5) Never use an impact wrench to remove or install temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector, insert the tester probe carefully to prevent terminals
from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Work in a place with good air ventilation and without anything that could ca\
use combustionaround you such as a welder, grinder, drill, electric motor or stove.
(2) Never work in a place such as a pit or nearby a pit, as there is a possi\
bility that vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting operations.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and donot spray much water so as to prevent slipping.
(3) Never use any electric equipment like an electric motor or a working lig\
ht, as they may create
sparks or a high temperature.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of shop rags containing fuel deposits separately.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKEPARTS
(a) If any metal tip is mixed in the inlet pass, this may give a bad effect to the engine and turbocharger.
(b) When removing and installing the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean waste cloth or gum tape.
(c) When installing the inlet system parts, check that there is no mixing of a metal tip.
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010B5±11
D25082
Rubber Attachment
D27697
: SUPPORT POSITION, PAN
TOGRAPH JACK POSITION
: CENTER OF VEHICLE GRAVITY
(unload condition)
: JACK POSITION
±
INTRODUCTION REPAIR INSTRUCTION
01±19
AVENSIS REPAIR MANUAL (RM1018E)
VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP
(a) As a rule, the vehicle must be unloaded when jacking up. Never jack up o\
r lift up the vehicle loaded
with things of heavy weight.
(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling,\
or hold the jacking support
location using the mission jack.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the instruction manual for a safety operation.
(b) Do not damage tires or wheels with a free wheel beam.
(c) Using a wheel stopper, fix the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in the flat place using a wheel stopper at all times.
(b) Use a safety stand with a rubber attachment, as shownin the illustration.
(c) Support the specified location with a jack and safety stand accurately.
(d) When jacking up the front wheels, release the parking
brake and place wheel stoppers only behind the rear
wheels. When jacking up the rear wheels, place wheel
stoppers only in front of the front wheels.
(e) Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with a safety stand.
(f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels that contact ground.
(g) When jacking down the vehicle with its front wheels jacked up, release t\
he parking brake and place wheel stoppers only in front of the rear wheels. When jacking down the v\
ehicle with its rear wheels
jacked up, place wheel stoppers only behind the front wheels.
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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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031DZ±02
03±6
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle position sensor x Throttle body assy2.02018 in.
lbf
ISC valve x Throttle body assy3.73833 in.
lbf
Accelerator control cable bracket x Throttle body assy1313310
Throttle body assy x Intake manifold3030622
Throttle body bracket x Cylinder block sub±assy (1ZZ±FE)3030622
Manifold stay No. 2 x Throttle body assy (M/T)1313310
Accelerator control cable assy x Accelerator control cable bracket131299
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold3030622
Accelerator control cable assy x Throttle body assy131299
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Knock sensor x Cylinder block sub±assy2020415
Intake manifold x Cylinder head sub±assy3030622
Variable resister x Body (Leaded gasoline (Steering position LHD))5.05144 in.
lbf
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Throttle body assy x Intake manifold9.09280 in.
lbf
Throttle body bracket x Throttle body assy2121015
Throttle body bracket x Cylinder head sub±assy2121015
Ground terminal x Throttle body bracket8.48674 in.
lbf
Wire harness protector x Throttle body bracket8.48674 in.
lbf
Air cleaner hose No. 1 x Throttle body assy1.51513 in.
lbf
Engine cover sub±assy No. 1 x Cylinder head cover sub±assy7.07162 in.
lbf
Accelerator pedal x Body5.45548 in.
lbf
Knock control sensor x Cylinder block2020415
Engine cover bracket x Cylinder head3838828
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Intake shutter assy x Intake air connector2121415
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Air tube No. 2 x Transmission2525518
Air tube No. 1 x Air tube No. 22525518
Camshaft position sensor x Camshaft oil seal retainer8.89079 in.
lbf
Return tube sub±assy x Engine hanger No. 19.09280 in.
lbf
Crankshaft position sensor x Oil pump assy8.89079 in.
lbf
ECM x Body5.55649 in.
lbf
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0313B±05
03±34
±
SERVICE SPECIFICATIONS FRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
SERVICE DATA
Vehicle height
(Normal package) Front: A *1 ± B *2
Rear: D *4 ± C *3
(Rough road package) Front: A *1
± B *2
Rear: D *4 ± C *3
92 mm (3.62 in.)
61 mm (2.40 in.)
72 mm (2.83 in.)
41 mm (1.61 in.)
Toe±in (total)
Rack end length difference0
06'
12' (0.1

0.2
), 1
2 mm (0.04
0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle
[Electric motor power steering]
(Normal package) Inside wheel Outside wheel: Reference
(Rough road package) Inside wheel Outside wheel: Reference
\b\f
17'  2
\b\f\f
 

32
52' \b\f

\b\f
42'  2
\b\f
 

33
16' \b\b

Front wheel align-
ment
Wheel angle
[Oil pressure power steering]
(Normal package) Inside wheel
Outside wheel: Reference
(Rough road package) Inside wheel Outside wheel: Reference
\b
47'  2
\b \f
 

31
15' \b

\b
09'  2
\b

 

31
38' \b
\b

Camber
Normal package
Rough road package
Right±left error
±0
34'  45' (±0.57
 0.75
)
±0
19'  45' (±0.32
 0.75
)
45' (0.75
) or less
Caster
Normal package
Rough road package
Right±left error

54'  45' (2.90
 0.75
)

40'  45' (2.67
 0.75
)
45' (0.75
) or less
Steering axis inclination
Normal package
Rough road package
Right±left error
12
27'  45' (12.45
 0.75
)
11
56'  45' (11.93
 0.75
)
45' (0.75
) or less
Front suspensionLower ball joint turning torque0.98 ± 4.9 N´m (10 ± 50 kgf´cm, 9 ± 43 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
*1: Ground clearance of front wheel center
*2: Ground clearance of lower suspension arm front bolt center
*3: Ground clearance of toe control arm inner bolt center
*4: Ground clearance of rear wheel center
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