sst TOYOTA AVENSIS 2003 Service Manual Online

±
FUELINJECTOR ASSY(1CD±FTV)
11±65
AVENSIS REPAIR MANUAL (RM1018E)
23.INSTALL INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
24.INSTALL INJECTION PIPE SUB±ASSY NO.3
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
25.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
26.INSTALL AIR TUBE NO.1 (See page 14±270)
27. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
28. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
29. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
30. CHECK FOR FUEL LEAKS
NOTICE:
Under ACTIVE TEST mode, fuel pressure increases. Take precautions to prevent fuel from spraying
on you or inside the engine compartment.
HINT:
During ACTIVE TEST mode, engine speed goes high and combustion noise bec\
omes loud.
(a) Check that there are no fuel leaks from any part of the fuel system at t\
he engine stops.
HINT:
If fuel leakage could be found on specific parts, replace them with new \
parts.
(b) While cranking or when starting the engine, check that there is no leaks from\
any part of the fuel sys-
tem.
HINT:
If fuel leakage could be found on specific parts, replace them with new pa\
rts.
(c) Disconnect the fuel hose from the common rail.
(d) While cranking the engine, check fuel leaks from the return pipe.
HINT:
If there is fuel leakage, replace the common rail.
(e) Connect the hand±held tester to the DLC3.
(f) Start the engine and push the hand±held tester main switch ON.
(g) Select the FUEL LEAK test of ACTIVE TEST mode on the hand±held tester\
.
(h) If you do not have the hand±held tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this opera\
tion several times.
(i) Check that there are no leaks from any part of the fuel system.
NOTICE:
If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in\
a minute, it is acceptable.
HINT:
If fuel leakage could be found on specific parts, replace them with new \
parts.
(j) Reconnect the fuel hose to the common rail.
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1209F±02
A62250
Port APort BPort C
A60562
Cylinder Head Side
A60563
Intake Manifold Side
Gasket
B11870
12±8
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT CHARCOAL CANISTER ASSY
(a) Inspect charcoal canister operation. (1) Check the charcoal canister operation according tothe table below.
SST 09992±00242
Inspection:
Checking methodResult
Close ports B and C, then apply vacuum
to port ANo leaks
Close port C, then apply vacuum to port
AAir flows from port B
Close port C, then blow air into port AAir flows from port B
Blow air into port AAir flows from ports B and C
2. INSPECT VENTILATION VALVE SUB±ASSY
(a) Install clean hose to the PCV valve.
(b) Inspect the PCV valve operation. (1) Blow air into the cylinder head side, and check thatair passes through easily.
CAUTION:
Do not suck air through the valve. If contains petroleum
substances and is harmful.
(2) Blow air into the intake manifold side, and checkthat air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
(c) Remove clean hose from the PCV valve.
3. INSPECT FUEL TANK CAP ASSY
(a) Visually check if the cap or gasket is deformed or dam- aged.
If necessary, repair or replace the cap.
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1209H±02
A62250
Port APort BPort C
A60562
Cylinder Head Side
A60563
Intake Manifold Side
Gasket
B11870
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FSE)
12±13
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT CHARCOAL CANISTER ASSY
(a) Inspect charcoal canister operation.
(1) Check the charcoal canister operation according tothe table below.
SST 09992±00242
Checking methodResult
Close ports B and C, then apply vacuum
to port ANo leaks
Close port C, then apply vacuum to port
AAir flows from port B
Close port C, then blow air into port AAir flows from port B
Blow air into port AAir flows from ports B and C
2. INSPECT VENTILATION VALVE SUB±ASSY
(a) Install clean hose to the PCV valve.
(b) Inspect the PCV valve operation. (1) Blow air into the cylinder head side, and check thatair passes through easily.
CAUTION:
Do not suck air through the valve. If contains petroleum
substances and is harmful.
(2) Blow air into the intake manifold side, and checkthat air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
(c) Remove clean hose from the PCV valve.
3. INSPECT FUEL TANK CAP ASSY
(a) Visually check if the cap or gasket is deformed or dam- aged.
If necessary, repair or replace the cap.
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1209D±02
A62250
Port APort BPort C
A77115
Ohmmeter
Resistance
A77116
Ohmmeter
No continuity
A77117
Air
E
F
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1ZZ±FE/3ZZ±FE)
12±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT CHARCOAL CANISTER ASSY
(a) Inspect charcoal canister operation.
(1) Check the charcoal canister operation according tothe table below.
SST 09992±00242
Inspection:
Checking methodResult
Close ports B and C, then apply vacuum
to port ANo leaks
Close port C, then apply vacuum to port
AAir flows from port B
Close port C, then blow air into port AAir flows from port B
Blow air into port AAir flows from ports B and C
2. INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect VSV for open circuit. (1) Using an ohmmeter, measure resistance betweenthe terminals.
Resistance: 26 to 30
at 20
C (68
F)
If the resistance is not as specified, replace the VSV.
(b) Inspect the VSV for ground. (1) Using an ohmmeter, check that there is no continu-ity between each terminal and the body.
If there is continuity, replace the VSV.
(c) Inspect the VSV operation.
(1) Check that air flows with a little difficulty from port Eto port F.
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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.
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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
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141BQ±01
A77339
A77284
14±240
±
ENGINE MECHANICALCAMSHAFT(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±30)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER RH 5.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove the 2 nuts and the engine cover No. 1.
6.REMOVE IGNITION COIL ASSY
(a)Remove the 4 bolts and the ignition coils.
7.REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
8.REMOVE FUEL TUBE SUB±ASSY (See page 11±33)
9.REMOVE FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
10.REMOVE FUEL PUMP ASSY (See page 11±52)
11.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timingmark 0 of the timing chain cover.
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A77395
Engine
Front
A77396
HookPinTurn
Disconnect
A77397
Push Turn
Plunger
±
ENGINE MECHANICALCAMSHAFT(1AZ±FSE)
14±245
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install a new gasket chain tensioner No. 1 with 2 nuts.
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
NOTICE:
If the hook is disengaged while installing, apply the hook
again, and then resume the installation.
(c)Turn the crankshaft counterclockwise, and check that the
pin is disengaged from the hook.
(d)Turn the crankshaft clockwise, and check the plunger is extended.
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 14±222)
22.INSTALL FUEL PUMP ASSY (See page 11±52)
23.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
24.INSTALL FUEL TUBE SUB±ASSY (See page 11±30)
25.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
26. INSTALL IGNITION COIL ASSY Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
27. CHECK FOR ENGINE OIL LEAKS
28. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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A79428
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part

Gasket
18 (184, 13)
27 (270, 20)22 (224, 16)13 (135, 9.7)

Gasket

O±ring
Fuel Injector
Back±up Ring No. 1



Injection Nozzle Seat
8.8 (90, 78 in.
lbf)

Oil Seal
8.8 (90, 78 in.
lbf)
20 (204, 15)
Washer
Nozzle Holder Clamp Nozzle Leakage
Pipe Assy
Injector Assy Cylinder Head Cover Sub±assy
Gasket
Camshaft Bearing Cap No. 2 Camshaft Camshaft
Camshaft Carrier
Camshaft Oil Seal
Retainer
88 (899, 65)
Camshaft Timing Pulley Set Key
20 (204, 15)
* 42 (428, 31)
46 (469, 34)
Injection Pipe
Clamp No. 2
Injection Pipe
Sub±assy


O±ring
21 (214, 15)
Vacuum Pump Assy
5.0 (51, 44 in.
lbf)

Nozzle Holder Seal
* Use SST
* 42 (428, 31)
46 (469, 34)
±
ENGINE MECHANICAL CAMSHAFT (1CD±FTV)
14±317
AVENSIS REPAIR MANUAL (RM1018E)
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141C8±01
SSTA61187
14±318
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
3.ENGINE UNDER COVER RH
4.REMOVE RADIATOR SUPPORT OPENING COVER
5.REMOVE ENGINE ROOM COVER SIDE
6.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
7.REMOVE AIR CLEANER ASSY (See page 11±60)
8.REMOVE VACUUM RESERVOIR SUB±ASSY
(a)Disconnect the 2 vacuum hoses and the connector.
(b)Remove the 2 bolts and the vacuum reservoir.
9.REMOVE AIR TUBE NO.1 (See page 14±270)
10.REMOVE INJECTOR DRIVER (See page 14±286)
11. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
12.REMOVE GENERATOR V BELT (See page 14±269)
13.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
14.REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH (See page 14±307)
15.REMOVE CRANKSHAFT PULLEY (See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
16.REMOVE IDLER PULLEY SUB±ASSY (See page 14±307)
17.REMOVE TIMING BELT NO.2 COVER (See page 14±307)
18.REMOVE TIMING BELT NO.1 COVER (See page 14±307)
19. REMOVE TIMING BELT GUIDE
20.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14±307)
21.SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14±307)
22.REMOVE TIMING CHAIN COVER PLATE (See page 14±307)
23.REMOVE TIMING BELT (See page 14±307)
24.REMOVE CAMSHAFT POSITION SENSOR (See page 10±63)
25. REMOVE CAMSHAFT TIMING PULLEY
(a) Using SST, remove the pulley bolt.SST 09960±10010 (09962±01000, 09963±01000)
(b) Remove the timing pulley.
HINT:
Using a plastic±faced hammer, tap out the pulley.
(c) Remove the set key.
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