TOYOTA AVENSIS 2003 Service Repair Manual

A64007
Front90

Clamp
Bolt
±
INTAKEINTERCOOLER ASSY(1CD±FTV)
13±19
AVENSIS REPAIR MANUAL (RM1018E)
(c)Tighten the hose clamps as shown in the illustration.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
5.INSTALL INTERCOOLER COOLING AIR DUCT SUB±ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
6.INSTALL FRONT BUMPER COVER (See page 76±3)
http://vnx.su

13030±02
A60591
A60592
A60593
Air
E G
A60594
Air
Filter Battery
E
±
INTAKE TURBO CHARGER SYSTEM (1CD±FTV)
13±7
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect VSV for open circuit.
(1) Using an ohmmeter, check that the there is continu-ity between the terminals.
Resistance: 37 ± 44
at 20
C (68
F)
(b) Inspect VSV for ground. (1) Using an ohmmeter, check that there is no continu-ity between each terminal and the body.
Specified condition: No continuity
(c) Inspect VSV operation. (1) Check that air flows from port E to G.
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to filter.
http://vnx.su

1302Z±03
A77123
SST
A60595E2 VC
±
INTAKE TURBO CHARGER SYSTEM (1CD±FTV)
13±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
(a) Check for leakage or clogging between the air cleaner
housing and turbocharger inlet and between the turbo-
charger outlet and cylinder head.
(1) Clogged air cleaner...Clean or replace element
(2) Hoses collapsed or deformed...Repair or replace
(3) Leakage from connections...Check each connec-tion and repair
(4) Cracks in components...Check and replace
2. INSPECT EXHAUST SYSTEM
(a) Check for leakage or clogging between the cylinder head
and turbocharger inlet and between the turbocharger out-
let and exhaust pipe.
(1) Deformed components...Repair or replace
(2) Foreign material in passages...Remove
(3) Leakage from components...Repair or replace
(4) Cracks in components...Check and replace
3. CHECK TURBOCHARGING PRESSURE
(a) Warm up the engine.
(b) Using a 3±way connector, connect SST (turbocharger pressure gauge) to the hose leading to the intake air con-
nector.
SST 09992 ± 00242
(c) While depressing the clutch pedal, press the accelerator pedal down to the full. Measure the turbocharging pres-
sure at maximum speed (5,100 to 5,250 rpm).
Standard pressure:
15 to 45 kPa (0.15 to 0.46 kgf/cm
2, 2.2 to 6.5 psi)
If the pressure is less than specification, check both the intake
air and exhaust systems for leakage.
If there is no leakage, check if the actuator hose has discon-
nected. If not, check the turbocharger.
If the pressure is greater than specification, check if the actua-
tor hose has disconnected or cracked. If not, check the turbo-
charger.
4. INSPECT TURBO PRESSURE SENSOR
(a) Inspect power source voltage (1) Disconnect the turbo pressure sensor connector.
(2) Turn the ignition switch ON.
(3) Using a voltmeter, measure the voltage between
connector terminals 3 (VC) and 1 (E2) of the wiring
harness side.
Voltage: 4.5 to 5.5 V
(4) Turn the ignition switch OFF.
(5) Reconnect the turbo pressure sensor connector.
http://vnx.su

A79448
PIM (+)
E2 (±) ECM
Vacuum
SST
A77125
SST
Pressure
13±6
±
INTAKE TURBO CHARGER SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Inspect supply power (1) Turn the ignition switch ON.
(2) Disconnect the vacuum hose from the turbo pres-sure sensor.
(3) Connect a voltmeter to terminals 35 (PIM) and 28 (E2) of the ECM and measure the output voltage
under atmospheric pressure.
(4) Apply vacuum to the turbo pressure sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 66.7 kPa
(500 mmHg, 19.96 in.Hg).
(5) Measure the voltage decrease from step (3) above for each segment.
Voltage drop:
Apply Vacuum
[kPa (mmHg, in.Hg)]Voltage Decrease [V]
13.3 (100, 3.94)0.1 to 0.3
26.7 (200, 7.87)0.3 to 0.5
40.0 (300, 11.81)0.5 to 0.7
57.3 (400, 15.75)0.7 to 0.9
66.7 (500, 19.96)0.9 to 1.0
(6) Using SST (turbocharger pressure gauge), applypressure to the turbo pressure sensor in 19.6 kPa
(0.20 kgf/cm
2, 2.84 psi) segments to 98.0 kPa (1.00
kgf/cm
2, 14.2 psi).
SST 09992±00242
(7) Measure the voltage increase from step (3) above for each segment.
Voltage up:
Applied Pressure
[kPa (kgf/cm2, psi)]
Voltage Increase [V]
19.6 (0.20, 2.84)0.1 to 0.4
39.2 (0.40, 5.69)0.4 to 0.7
58.8 (0.60, 8.53)0.7 to 1.0
78.5 (0.80, 11.4)1.0 to 1.3
98.0 (1.00, 14.2)1.3 to 1.6
http://vnx.su

1302Y±03
A77119
A77120
A77121
±
INTAKE TURBO CHARGER SYSTEM (1CD±FTV)
13±3
AVENSIS REPAIR MANUAL (RM1018E)
TURBO CHARGER SYSTEM (1CD±FTV)
PRECAUTION
1. MAINTENANCE PRECAUTION
(a) Do not stop the engine immediately after pulling a trailer,
or after driving at a high speed, or uphill drive. Let the en-
gine Idle for 20 to 120 seconds before turn the ignition
switch OFF (According as the driving condition, the idling
time varies).
(b) Avoid quick acceleration or quickly accelerating the en- gine RPM immediately after the starting a cold engine.
(c) If the turbocharger is found to be defective, it must be re-
placed. Also, inspect a source of the trouble including
conditions of the turbocharger that having been used. Re-
pair or replace the followings as necessary:
(1) Engine oil (Level and quality)
(2) Oil lines leading to the turbocharger
(d) Pay due attention when removing and reinstalling the turbocharger assembly. Do not drop, or do not give shock,
or do not grasp easily±deformed assembly parts such as
the actuator or push rod in removal and reinstallation.
(e) Before removal, cover both the intake and exhaust ports
and the oil inlet to prevent dirt or foreign objects from be-
ing introduced.
(f) If replacing the turbocharger, check for deposits in the oil pipe. If necessary, replace the oil pipe too.
(g) Thoroughly remove old gasket sticking to the lubrication oil pipe flange and the turbocharger oil flange.
(h) If replacing the bolt(s) or nut(s), must use Toyota genuine parts to prevent breakage or deformation.
(i) If replacing the turbocharger, put 20 cm
3 (1.2 cu in.) of
fresh oil into the turbocharger oil inlet hole and turn the tur-
bine wheel by hand to spread oil to the bearing.
(j) If overhauling or replacing the engine, cut the fuel supply after reassembly and crank the engine for 30 seconds to
feed oil throughout the engine then run the engine at idle
for 60 seconds.
http://vnx.su

A77122
13±4
±
INTAKE TURBO CHARGER SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(k) Since the turbine wheels runs at an extremely high speed, if the engine is running without the air cleaner, case cover
and hose, damage to the turbine wheel will result by
introduced foreign particle.
http://vnx.su

1306Y±01
A79439
8.0 (82, 71 in.
lbf)
Engine Cover No. 1 Radiator Support Opening Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
7.0 (71, 62 in.
lbf)
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Engine Under Cover Sub±assy No. 1
Clip
Retainer
Clip
13±8
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
TURBOCHARGER SUB±ASSY (1CD±FTV)
COMPONENTS
http://vnx.su

A79440
Union To Connector Tube Hose
Fuel Filter Assy
Vacuum Reservoir Sub±assy
43 (440, 32)
43 (440, 32)


Gasket

Gasket Compression Spring
Floor Panel Brace Front
Exhaust Pipe Assy Front
Compression Spring
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part
Intercooler Air Hose

Gasket
7.5 (76, 66 in.
lbf)
Exhaust Pipe Assy
30 (302, 22)
7.5 (76, 66 in.
lbf)
Heater Bracket
Heater Pump Assy25 (255, 18)
25 (255, 18)
7.5 (76, 66 in.
lbf)
18 (178, 13)
7.5 (76, 66 in.
lbf)
w/ Cold Area:
w/ Cold Area:
w/ Cold Area:
8.3 (85, 73 in.
lbf)
Air Tube No. 1
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
13±9
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

A79441
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket

Gasket


Gasket
20 (204, 15)
20 (204, 15)
20 (204, 15)
12 (122, 8.9)
53 (540, 39)
13 (135, 9.7)
36 (367, 27)
61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay Turbocharger Sub±assy
Turbo Oil Inlet Pipe
Sub±assy
Manifold Stay
Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy
Turbo Insulator No. 2
Turbo Water Pipe
Sub±assy No. 1
13 (135, 9.7)
56 (571, 41)
Turbo Water
Hose No. 2
Turbo Water
Hose No. 1

Gasket
12 (122, 8.9)


13±10
±
INTAKE TURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

1306Z±01
A79155
A80093
A79158
±
INTAKETURBOCHARGER SUB±ASSY(1CD±FTV)
13±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
2.DRAIN ENGINE COOLANT(See page 16±44)
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
5.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
6.REMOVE AIR CLEANER ASSY
(a)Disconnect the PCV hose and 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. 7.REMOVE INTERCOOLER AIR HOSE
(a)Remove the 3 bolts and nut, separate the air tube No.1.
(b)Loosen the hose clamp bolts and remove the air hoseNo.1.
8.REMOVE FUEL FILTER ASSY(See page 11±82) 9. SEPARATE HEATER PUMP ASSY (W/ COLD AREA)
(a) Remove the nut and disconnect the connector.
(b) Separate the heater pump.
http://vnx.su