DIAGNOSIS TOYOTA AVENSIS 2003 Service Repair Manual

010B2±13
N17080
Filler Cap
Float
Reservoir Tank
Grommet
Clip
Slotted Spring Pin
: Specified torque

Non±reusable part Cylinder
Piston
Push Rod
Washer
Snap Ring
Boot


Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
±
INTRODUCTION HOW TO USE THIS MANUAL
01±1
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO USE THIS MANUAL
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 processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking \
and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ºDiagnosisº (found in the ºDiagnosticsº section), the 2nd
pro-
cess of ºRemoving and Installing, Replacing, Disassembling, Installing and Ch\
ecking, and Adjustingº,
but the 3rd process of ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a refe\
rence to help you find 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 repair situation. Be sure to use SST and SSM when they are requir\
ed 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 under the title where necessary.
(b) Non±reusable parts, grease application area, precoated parts and tigh\
tening torque are specified in the component drawings.
Example:
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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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022LX±01
±
PREPARATION DIAGNOSTICS
02±1
AVENSIS REPAIR MANUAL (RM1018E)
DIAGNOSTICS
PREPARATION
SST
09243±00020Idle Adjusting Screw WrenchSFI SYSTEM(1AZ±FE)
09843±18040Diagnosis Check Wire No.2AIR CONDITIONING SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
SUPPLEMENTAL RESTRAINT
SYSTEM
SFI SYSTEM(1AZ±FE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
09992±00242Turbocharger Pressure GaugeECD SYSTEM(1CD±FTV)
Recomended Tools
09082±00040TOYOTA Electrical TesterCOMBINATION METER
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)
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±
PREPARATION ENGINE MECHANICAL
02±11
AVENSIS REPAIR MANUAL (RM1018E)
(09330±00030)PinPARTIAL ENGINE ASSY(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
09520±01010Drive Shaft Remover AttachmentENGINE REAR OIL SEAL(1CD±FTV)
09520±24010Differential Side Gear Shaft
PullerENGINE REAR OIL SEAL(1CD±FTV)
(09520±32040)Shocker SetENGINE REAR OIL SEAL(1CD±FTV)
09628±62011Boll Joint PullerENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09670±00010Front Crossmember Guide ToolENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09817±33190Sensor Socket WrenchPARTIAL ENGINE ASSY(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09843±18020Diagnosis Check WireENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
09843±18040Diagnosis Check Wire No.2ENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1CD±FTV)
ENGINE(1ZZ±FE/3ZZ±FE)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
09930±00010Drive Shaft Nut ChiselENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
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022KW±01
02±54
±
PREPARATION WIPER & WASHER
AVENSIS REPAIR MANUAL (RM1018E)
WIPER & WASHER
PREPARATION
SST
09843±18040Diagnosis Check Wire No.2WIPER AND WASHER SYSTEM
Recomended Tools
09042±00010Torx Socket T30WINDSHIELD WIPER MOTOR ASSY
09082±00040TOYOTA Electrical TesterWIPER AND WASHER SYSTEM
(09083±00150)Test Lead SetWIPER AND WASHER SYSTEM
Equipment
Torque wrench
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100G6±02
A75903
Air
A79035
VG
EVG
A79035E2
PSW
10±18
±
ENGINE CONTROL SYSTEMSFI SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
SFI SYSTEM(1AZ±FE)
ON±VEHICLE INSPECTION
1.INSPECTMASS AIR FLOW METER
(a)If you have hand±held tester: Inspect for operation
(1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON.
(3)Blow air into the MAF meter, and check that the airflow fluctuates (MAF) of the ºDIAGNOSIS / OBD/
MOBD / DATA LIST / ALLº shown the standard val-
ue.
If operation is not as specified, check the MAF meter (See page
10±20), wiring and ECM.
(b)If you have no hand±held tester: Inspect for operation
(1)Turn the ignition switch ON.
(2)Connect the positive tester probe of the voltmeterto the terminal VG of the ECM. and the negative tes-
ter probe of the voltmeter to the terminal EVG of the
ECM.
(3)Blow air into the MAF meter, and check that the volt- age fluctuates.
If operation is not as specified, check the MAF meter (See page
10±20), wiring and ECM.
2. INSPECT POWER STEERING OIL PRESSURE SEN- SOR
(a) Using a voltmeter, measure the voltage between termi-
nals PSW and E2.
Voltage:
ConditionVoltage (V)
Not spin the steering wheel at engine idling9 to 14
Spin the steering wheel at engine idling0 to 3
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100EX±02
A75903
Air
A79035
VG
EVG
A79035
E2
EMPS
±
ENGINE CONTROL SYSTEMSFI SYSTEM(1ZZ±FE/3ZZ±FE)
10±1
AVENSIS REPAIR MANUAL (RM1018E)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
1.INSPECTMASS AIR FLOW METER
(a)If you have hand±held tester:
Inspect for operation
(1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON.
(3)Blow air into the MAF meter, and check that the airflow fluctuates (MAF) of the ºDIAGNOSIS / OBD/
MOBD / DATA LIST / ALLº shown the standard val-
ue.
If operation is not as specified, check the MAF meter (See page
10±3), wiring and ECM.
(b)If you have no hand±held tester: Inspect for operation
(1)Turn the ignition switch ON.
(2)Connect the positive tester probe of the voltmeterto the terminal VG of the ECM. and the negative tes-
ter probe of the voltmeter to the terminal EVG of the
ECM.
(3)Blow air into the MAF meter, and check that the volt- age fluctuates.
If operation is not as specified, check the MAF meter (See page
10±3), wiring and ECM.
2. INSPECT POWER STEERING OIL PRESSURE SWITCH
(a) Using a voltmeter, measure the voltage between termi-
nals EMPS and E2.
Voltage:
ConditionVoltage (V)
Not spin the steering wheel at engine idling8 to 14
Spin the steering wheel at engine idling0 to 1.5
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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:
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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)
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Z15500
Oil
ReservoirPS Vane
Pump
PS Gear
SST(s)
Open
Lock Position
F08858
±
POWER STEERING POWER STEERING SYSTEM
51±7
AVENSIS REPAIR MANUAL (RM1018E)
(k) With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
Minimum fluid pressure:
AZ Series:
8,300 to 9,000 kPa (85 to 92 kgf/cm
2, 1,204 to 1,305 psi)
1CD±FTV:
8,800 to 9,500 kPa (90 to 97 kgf/cm
2, 1,276 to 1,378 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(l) Remove SST(s).
(m) AZ Series:
Connect the pressure feed tube assy to the vane pump
assy (See page 51±9).
(n) 1CD±FTV:
Connect the pressure feed tube assy to the vane pump
assy (See page 51±19).
(o) Bleed the power steering system.
5. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b)Remove the steering wheel pad (See page 60±17).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions. Steering effort (Reference):
5.5 N´m (56 kgf´cm, 49 in.´lbf)
HINT:
Take the tire type, pressure and contact surface into consider-
ation before making your diagnosis.
(e) Torque the steering wheel set nut. Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
(f)Install the steering wheel pad (See page 60±17).
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