TOYOTA AVENSIS 2003 Service Repair Manual

14±104
±
ENGINE MECHANICAL ENGINE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E) CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:


Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

ISC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:

Faulty pressure regulator

Defective water temperature sensor

Defective mass air flow meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor
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141CP±01
CG
TCA51075
A79034
±
ENGINE MECHANICALENGINE(1AZ±FSE)
14±181
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FSE)
INSPECTION
1.INSPECT COOLANT (See page 16±25)
2.INSPECT ENGINE OIL(See page 17±13)
3.INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±14)
6.INSPECT V±RIBBED BELT
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12 BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040, 09843±18020
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
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TA C
A52006
14±182
±
ENGINE MECHANICAL ENGINE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 23  BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester: (1) Connect the hand±held tester to the DLC3.
Idle speed: 625 to 725 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester: (1) Using SST, connect the tachometer test prove toterminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 625 to 725 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
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A79033
±
ENGINE MECHANICALENGINE(1AZ±FSE)
14±183
AVENSIS REPAIR MANUAL (RM1018E)
(e)Inspect cylinder compression pressure.
SST09992±00500
(1)Insert a compression gauge into the spark plughole.
(2)Fully open the throttle.
(3)While cranking the engine, measure the compres- sion pressure.
Compression pressure:
1,300 kPa (13.3 kgf/cm
2, 189 psi)
Minimum pressure:
1000 kPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi)
NOTICE:

Always use a fully charged battery to obtain engine
speed of 250 rpm or more.

Check other cylinder's compression pressure in the
same way.

This measurement must be done in as short a time as
possible.
(4)If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the
spark plug hole and inspect again.
HINT:

If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.

If pressure stays low, a valve may be sticking or seating
improperly, or there may be leakage past the gasket.
10.INSPECT CO/HC
(a)Start the engine.
(b)Run the engine at 2,500 rpm for approximately 180 seconds.
(c)Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tail\
pipe during idling.
(d)Check CO/HC concentration at idle. Idle CO concentration: 0 to 0.5 %
Idle HC concentration: Applicable local regulation
(e)If the CO/HC concentration does not conform to specifications, perform troubleshooting in the order given below.
(1)Check heated oxygen sensor operation. (See page 12±6)
(2) See the table below for possible causes, and then inspect and repair the applicable causes ifnecessary.
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14±184
±
ENGINE MECHANICAL ENGINE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E) CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:


Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

ISC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI systems:

Faulty pressure regulator

Defective water temperature sensor

Defective mass air flow meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor
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140DD±03
A57063
Measure Point for Belt
Deflection and Tension
Alternator
Crankshaft Compressor
P/S P/S
Alternator Crankshaft
A/C equipped
A/C not equipped
A61173
B
A
14±266
±
ENGINE MECHANICALENGINE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1CD±FTV)
INSPECTION
1.INSPECT COOLANT (See page 16±37)
2.INSPECT ENGINE OIL (See page 17±20)
3.INSPECT BATTERY (See page 19±26)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY 5. INSPECT DRIVE BELT
(a) Inspect vane pump V belt.(1) Measure the belt deflection
Pressing force: 98 N
m (10 kgf 22 lbf)
New belt
mm (in.)Used belt mm (in.)
A/C equipped9.5 to 11.5
(0.37 to 0.45)12.5 to 15.5
(0.49 to 0.61)
A/C not equipped10 to 12
(0.39 to 0.47)14 to 17
(0.55 to 0.67)
(2) Measure the belt tension
New belt
N (kgf, lbf)Used belt
N (kgf, lbf)
A/C equipped519 to 755
(53 to 77, 117 to 170)196 to 392
(20 to 40, 44 to 88)
A/C not equipped686 to 784
(70 to 80, 154 to 176)294 to 441
(30 to 45, 66 to 99)
NOTICE:

Check the drive belt deflection at the specified point.

When installing a new belt, set its tension value as
specified.

When inspecting the belt which is used over 5 min-
utes, apply the specifications of ºUsed Belt.º

When reinstalling the belt which is used over 5 min-
utes, adjust its deflection and tension to the medium
value in each specification of ºUsed Belt.º

V±ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.

When using a belt tension gauge, confirm the accura-
cy by using a master gauge first.
(b) Inspect generator V belt. (1) Check that the tension indicator is within range A onthe auto tensioner scale.
If the tension is not within the A range, replace the belt with a
new one.
HINT:
When replacing the drive belt with a new one, the belt tension
should be within the B range.
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TAC
A52006
A09593
SST
(Attachment)
±
ENGINE MECHANICALENGINE(1CD±FTV)
14±267
AVENSIS REPAIR MANUAL (RM1018E)
6.INSPECT ENGINE IDLE SPEED
(a)Using SST, connect a tachometer test prove to terminal
9 (TAC) of DLC3.
SST09843±18040
(b)Check the idle speed. Idle speed: 750 to 850 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
7.INSPECT MAXIMUM SPEED
(a)Start the engine.
(b)Depress the accelerator pedal to the limit.
(c)Check the maximum speed. Maximum speed: 5,100 to 5,250 rpm
8.INSPECT COMPRESSION
(a)Warm up the engine to normal operating temperature,and stop the engine.
(b)Remove the glow plugs. (See page 19±33)
(c) Disconnect the injector connectors.
(d) Inspect cylinder compression pressure.
(1) Install SST (attachment) to the glow plug hole.
SST 09992±00025 (09992±00121)
Torque: 12 N
m (125 kgf
cm, 95 ft
lbf)
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A61174
SST
Compression Gauge
14±268
±
ENGINE MECHANICAL ENGINE (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(2) Connect SST (compression gauge) to the SST (at- tachment).
SST 09992±00025 (09992±00211)
(3) Fully open the throttle valve, and start the engine.
(4) While cranking the engine, measure the compres-
sion pressure.
NOTICE:

Always use a fully charged battery to obtain engine
speed of 250 rpm or more.

Check other cylinder compression pressure in the
same way.

This measurement must be done in as short a time as
possible.
Compression pressure:
2,628 kPa (26.8 kgf/cm
2, 381 psi) or more
Minimum pressure:
2,157 kPa (22.0 kgf/cm
2, 312 psi) or more
Difference between each cylinder:
490 kPa (5.0 kgf/cm
2, 71 psi) or less
(5) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
glow plug hole and inspect again.
HINT:

If adding oil raises the compression, there are chances of
the piston rings and/or cylinder bore wear or damage.

If pressure stays low, a valve may be sticking or seating
improperly, or there may be leakage past the gasket.
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140KR±02
A62199
TCCG
A62200
±
ENGINE MECHANICALENGINE(1ZZ±FE/3ZZ±FE)
14±1
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1ZZ±FE/3ZZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±1)
2.INSPECT ENGINE OIL (See page 17±1)
3.INSPECT BATTERY (See page 19±5)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±3)
6.INSPECT FAN AND GENERATOR V BELT
HINT:
You don't need to check the belt deflection because auto tensioner is ado\
pted.
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:
(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester: (1) Using SST, connect terminal 13 (TC) and 4 (CG) ofthe DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the 2 nuts, and 2 clips, and then remove the cylinder head cover.
(3) Pull out the wire harness as shown in the illustration.
(4) Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
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TA C
A52006
A01037
14±2
±
ENGINE MECHANICAL ENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Inspect ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.
(6) Disconnect the terminal 13 (TC) and 4 (CG) of theDLC3.
(7) Inspect ignition timing at idle.
Ignition timing:
10 to 18 BTDC (1ZZ±FE)
3.5 to 11.5 BTDC (3ZZ±FE)
(8) Confirm that ignition timing to go advanced angle side when the engine rpm is increased.
(9) Remove the timing light.
(10) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester: (1) Connect the hand±held tester to the DLC3.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect the tachometer test prove toterminal 9 (TAC) of DLC3.
SST 09843±18040
(d) Check the idle speed. Idle speed: 600 to 700 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the ignition coil.
(c) Remove the spark plugs.
(d) Inspect cylinder compression pressure. SST 09992±00500
(1) Insert a compression gauge into the spark plughole.
(2) Fully open the throttle.
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