TOYOTA AVENSIS 2003 Service Repair Manual

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
http://vnx.su

±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)Abbreviations Meaning
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
NO.Number
O2SOxygen Sensor
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
http://vnx.su

01±10
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E) Abbreviations Meaning
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RRSRigid Rear Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RRRear
RRSRear±Wheel Drive
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free±Tronic
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRCTraction Control System
TURBOTurbocharge
TWCThree±Way Catalyst
U/DUnderdrive
U/SUndersize
http://vnx.su

±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)Abbreviations Meaning
VCVVacuum Control Valve
VENTVentilator
VINVehicle Identification Number
VPSVariable Power Steering
VSCVehicle Skid Control
VSVVacuum Switching Valve
VTVVacuum Transmitting Valve
VVT±iVariable Valve Timing±intelligent
W/With
WGNWagon
W/HWire Harness
W/OWithout
1STFirst
2NDSecond
2WDTwo Wheel Drive Vehicle (4 x 2)
3RDThird
4THFourth
4WDFour Wheel Drive Vehicle (4 x 4)
4WSFour Wheel Steering System
5THFifth
http://vnx.su

010BH±01
A54988
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part Camshaft Timing Tube Assy
Camshaft Drive Gear
Seal Washer
Camshaft Setting Oil Seal No. 2 Camshaft,
No. 4 Camshaft Sub±assy
Wave Washer Camshaft Driven Main Gear
Snap Ring Camshaft Timing Gear
Bolt Washer
Screw Plug
78 (790, 58)
15 (150, 11)
7.5 (80, 66 in.´lbf)
Camshaft Sub Gear
Camshaft,
No. 3 Camshaft Sub±assy
OVERHAUL
±
INTRODUCTION HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
01±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main pro\
cesses:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Che\
cking, Adjusting
3. Final Inspection
(c) This manual explains ºRemoving and Installing, Replacing, Disassembling, Installing and Checking, Adjustingº, but ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual, howev\
er these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to\
be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) \
may be required, depending on the repairing condition. Be sure to use SST and SSM when they are requi\
red and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ºdisassembled parts drawingº\
so that it enables you to understand the fitting condition of the components.
(c) Non±reusable parts, grease applied parts, precoated parts and tightening torque are \
specified in the components drawing.
Example:
http://vnx.su

Illustration:what to do and where Task heading: what to do
Detailed text:how to do task
Set part No. Component part No.
A59974
01±2
±
INTRODUCTION HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Tightening torque, oil applying position, and non±reusable parts are described \
as important points in the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustrati\
on. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the important points are described.
(f) Only items with points are described in the procedure, and the operational portion \
and content are placed using an illustration. In the explanations, details of the operational \
method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In th\
at case the details may be different from the actual vehicle.
(h) The procedures are presented in a step±by±step format: (1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information\
such as specificationsand warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce- dure to look up your specifications. The specifications are also found in th\
e Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.
http://vnx.su

±
INTRODUCTION HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
01±3
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI \
UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the En\
glish System.
Example:
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)
http://vnx.su

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)
http://vnx.su

±
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
http://vnx.su

01±14
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TCM
Transmission Control ModuleTransmission ECU, ECT ECU
TPThrottle PositionThrottle Position
TRTransmission Range±
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree±Way Catalytic Converter
Three±Way Catalytic (TWC)
Manifold Converter
CC
RO
TWC+OCThree±Way + Oxidation Catalytic ConverterCCR + CCo
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor
WOTWide Open ThrottleFull Throttle
WU±OCWarm Up Oxidation Catalytic Converter±
WU±TWCWarm Up Three±Way Catalytic Converter±
3GRThird Gear±
4GRFourth Gear±
http://vnx.su