check engine light TOYOTA AVENSIS 2003 Service Repair Manual

010B8±08
D25086
WRONGCORRECT
D25087
Looseness of CrimpingCore Wire Terminal
Deformation
Pull Lightly
01±32
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
ELECTRONIC CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS (1) Unless stated, all resistance is measured at an ambient temperature of 20 C (68 F). As the re-
sistance may be outside the specifications if measured at high temperatures imme\
diately after
the vehicle has been running, measurements should be made when the engine h\
as cooled
down.
(b) HANDLING OF CONNECTOR(1) When removing the connector with lock, press the
connector in the direction of the engagement and
remove the lock by lightly pressing the lock claw.
(2) When removing the connector, do not hold the har- ness, but hold the connector.
(3) Before connecting the connector, check that there is no deformation, damage or missing terminals.
(4) The connector with a lock should be securely con- nected until it makes a ºclickº sound.
(5) When checking the connector with a Toyota electri- cal tester, check it from the backside (harness side)
of the connector using a mini test lead.
NOTICE:

As a water proof connector cannot be checked from
the backside, check by connecting the sub±harness.

Do not damage the terminals by moving the inserted
tester needle.
(c) CONNECTOR CHECKING POINTS
(1) Checking when the connector is connected:By holding the connector, check the inserted condi-
tion and locking efficiency (engaged condition).
(2) Checking when the connector is removed: Check by lightly pulling the wire harness (missing
terminal, terminal crimping condition, core wire
break).
Check visually for any rust, metal particles, water
and bent terminals (rust, mixing of foreign object,
terminal deformation).
NOTICE:
When testing a gold±plated female terminal, always use a
gold±plated male terminal.
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D25083
Vibrate Slightly
Shake Slightly
Vibrate
Slightly
D25084
Malfunction
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±27
AVENSIS REPAIR MANUAL (RM1018E)
SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no symptoms occurs. In such cases\
, a thorough customer
problem analysis must be carried out. Then the same or similar conditions and e\
nvironment in which the
problem occurred in the customer's vehicle should be simulated. No matter how much experience a techni-
cian has, or how skilled he may be, if he proceeds to troubleshoot without c\
onfirming the problem symptoms,
he will tend to overlook something important in the repair operation and make a wrong guess somewhere,
which will only lead to a standstill. For example, for a problem which only o\
ccurs when the engine is cold,
or for a problem which occurs due to vibration caused by the road during d\
riving, etc., the problem can never
be determined when the engine is hot or when the vehicles is at a standsti\
ll. Since vibration, heat or water
penetration (moisture) is a likely cause for the problem which is difficult to reproduce, the symptom simulation
tests introduced here are effective measures in a point that the external causes are applied to the vehicle
in a stationary condition.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms should be confirmed, \
and the problem area or parts
must also be discovered. To do so, reduce the possible problem circuits according to the symptoms before
starting this type of test and have the hand±held tester connected beforehand\
. After that, carry out the symp-
tom simulation test, judging whether the circuit being tested is defective \
or normal and also confirming the
problem symptoms at the same time. Refer to the problem symptoms table of each system to narrow down
the possible causes of the symptom.
1. VIBRATION METHOD: When vibration seems to be
the major cause.
(a) PART AND SENSOR
(1) Apply slight vibration with your finger to the part ofthe sensor considered to be the problem cause and
check whether the malfunction occurs.
HINT:
Applying strong vibration to relays may result in open relays.
(b) CONNECTORS (1) Slightly shake the connector vertically and horizon-tally.
(c) WIRE HARNESS
(1) Slightly shake the wire harness vertically and hori-zontally.
The connector joint and fulcrum of the vibration are
the major areas that should be checked thoroughly.
2. HEAT METHOD: If the problem seems to occur when the area in question is heated.
(a) Heat the component that is the possible cause of the mal- function with a hair dryer or similar object. Check if the
malfunction occurs.
NOTICE:

Do not heat the components to more than 60 C
(140 F) (Temperature is limited to keep the compo-
nents from being damaged).
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D25085
B02389
ON
01±28
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)

Do not apply heat directly to the parts in the ECU.
3. WATER SPRINKLING METHOD: When the malfunc- tion seems to occur on a rainy day or in high±humid-
ity.
(a) Sprinkle water onto the vehicle and check if the malfunc- tion occurs.
NOTICE:

Never sprinkle water directly onto the engine
compartment, but indirectly change the temperature
and humidity by spraying a mist of water onto the ra-
diator front surface.

Never apply water directly onto the electronic compo-
nents.
HINT:
If a vehicle is subject to water leakage, the leaking water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, this factor must also be considered.
4. OTHERS: If the malfunction seems to occur when electrical load is excessive.
(a) Turn on all the electrical equipment including the heater blower, headlights, rear window defogger, etc., and check
if the malfunction occurs.
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±
ENGINE CONTROL SYSTEMECD SYSTEM(1CD±FTV)
10±55
AVENSIS REPAIR MANUAL (RM1018E)
(c)Inspect the air assist system.
(1)Start the engine and check that the CHKENG does not light up.
(2)Allow the engine to warm up to normal operating temperature.
(3)Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 800
50 rpm
NOTICE:
Perform inspection under condition without electrical load.
(d)After checking the above (b) to (d), perform the driving test and check that there is no sense of incon- gruity.
3.INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a)Connect the hand±held tester to the DLC3.
(b)Turn the ignition switch ON.
(c)Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value. Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depress: 2.6 to 4.5 V
(d)Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value.
Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depress: 3.4 to 5.3 V
If you have no hand±held tester, measure voltage between terminals (VPA1 ± EP1, VPA2 ± EP2) of the ECM
connector (See page 05±549).
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A53763
E2PSW
10±38
±
ENGINE CONTROL SYSTEMSFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
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
3.INSPECT THROTTLE BODY
(a)Inspect the throttle control motor for operating sound.(1)Turn the ignition switch ON.
(2)When turning the accelerator pedal position sensor lever, check the running sound of the motor.Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See page 10±39), wiring and ECM.
(b) Inspect the throttle position sensor.
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) When turning the accelerator pedal position sensor lever to the full±\
open position, check thatthe throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the
standard value.
Standard throttle valve opening percentage:
60 % or more
If operation is not as specified, check that the accelerator pedal positio\
n sensor (See page 10±39), wiring
and ECM.
If you have no hand±held tester, measure voltage between terminals (VTA1 ± E2, VTA2 ± E2) of the ECM
connector (See page 05±318).
(c) Inspect the air assist system.
(1) Start the engine and check that the CHK ENG does not light up.
(2) Allow the engine to warm up to normal operating temperature.
(3) Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700
50 rpm
NOTICE:
Perform inspection under condition without electrical load.
(d) After checking the above (b) to (d), perform the driving test and check that there is no sense of incon-
gruity.
4. INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a) Connect the hand±held tester to the DLC3.
(b) Turn the ignition switch ON.
(c) Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value.
Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depress: 2.6 to 4.5 V
(d) Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value. Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depress: 3.4 to 5.3 V
If you have no hand±held tester, measure voltage between terminals (VPA ± EPA, VPA2 ± EPA2) of the ECM
connector (See page 05±318).
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A77913
Turn
Push
A77914
Turn
A81621
Fuel Pipe
Clamp
Push
11±28
±
FUELFUEL INJECTOR ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Apply a light coat of spindle oil or gasoline on the place where a fuel delivery pipe contacts the O±ring.
(c)Push the fuel injector while twisting it back and forth to
install it to the fuel delivery pipe.
NOTICE:

Be careful not to twist the O±ring.

After installing the fuel injectors, check that they turn
smoothly. If not, reinstall it with a new O±ring.
8.INSTALL FUEL DELIVERY PIPE SUB±ASSY
(a)Install 4 new insulators and the 2 delivery pipe No. 1 spacers to the cylinder head.
(b)Place the fuel delivery pipe and the 4 fuel injectors togeth- er to the cylinder head.
NOTICE:
Be careful not to drop the fuel injectors when installing the
fuel delivery pipe.
(c)Temporarily install 2 bolts which are used to secure the fuel delivery pipe to the cylinder head.
(d)Check that the fuel injectors rotate smoothly.
If the fuel injectors do not rotate smoothly, the probable cause
is incorrect installation of O±ring. Replace with the O±ring.
(e)Tighten the 2 bolts. Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(f)Connect the 4 fuel injector connectors.
(g)Install the 2 wire harness clamps.
(h)Connect the ventilation hose.
9.CONNECT FUEL TUBE SUB±ASSY
(a)Push in the connector to the pipe until it makes ºclickº sound.
NOTICE:

Check if there is any damage or foreign objects on the
connected part.

After connecting, check if the connector and the pipe
are securely connected by pulling on them.
(b)Install the fuel pipe clamp.
10.INSTALL AIR CLEANER CAP SUB±ASSY
11.CHECK FOR FUEL LEAKS (See page 11±19)
12.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
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110U2±01
A77915
±
FUELFUEL PRESSURE PULSATION DAMPER
ASSY(1AZ±FE)11±29
AVENSIS REPAIR MANUAL (RM1018E)
FUEL PRESSURE PULSATION DAMPER ASSY(1AZ±FE)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±15)
2.REMOVE ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
3.REMOVE AIR CLEANER CAP SUB±ASSY (See page 10±26)
4.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±26)
SST09268±21010
5.REMOVE FUEL PRESSURE PULSATION DAMPERASSY
(a)Remove the 2 bolts, and then remove the fuel pressure pulsation damper.
6.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY
(a)Apply a light coat of spindle oil or gasoline to a new O±ring, and instal\
l it to the fuel pressure pulsation damper.
(b)Install the fuel pressure pulsation damper with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
7.CONNECT FUEL TUBE SUB±ASSY (See page 11±26)
8. INSTALL AIR CLEANER CAP SUB±ASSY
9.CHECK FOR FUEL LEAKS (See page 11±19)
10.INSTALL ENGINE COVER SUB±ASSY NO.1 (See page 10±26)
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A79187
O±ringBack±up ring
B08249
A80111
180

90
11±62
±
FUEL INJECTOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install new back±up rings and O±rings to each injector.
(c) Apply a light coat of engine oil onto the O±rings on each injector.
(d) Install the injector to the cylinder head.
NOTICE:
Fit the injectors to the nozzle seat.
(e) Install the nozzle holder clamp as shown in the illustration. Tighten the camshaft bearing cap bolt by hand to fix the
nozzle holder clamp.
NOTICE:

Pay attention to the mounting orientation of the wash-
er.

When temporarily attaching the nozzle holder clamp
and the mounting bolt, be careful not to orient them
at an angle.
HINT:
Apply a light coat of engine oil on the threads of the nozzle hold-
er clamp bolts.
(f) Install the injection pipe No. 1, No. 2, No. 3 and No. 4,
tighten the nuts by hand.
(g) Install new 5 gaskets and the leakage pipe No. 1. Tighten
the 4 hollow screws by hand.
(h) Tighten the 4 nozzle holder clamp bolts. Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(i) Remove the 4 injection pipes.
18. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Install the nozzle leakage pipe and 5 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint portion of the
gasket comes within the ranges shown in the illustration.
(b) Apply a light coat of oil onto the 4 hollow screws and the union bolt.
(c) Tighten the 4 hollow screws and the union bolt by hand.
(d) Tighten the 4 hollow screws and the union bolt. Torque:
18 N
m (184 kgf
cm, 13 ft
lbf) for hollow screw
22 N
m (224 kgf
cm, 16 ft
lbf) for union bolt
(e) Check that there are no leaks from the nozzle leakage pipe connection.
(1) Disconnect the fuel hose, and remove the bolt, thecheck valve and the nozzle leakage No. 2 pipe and
the gasket.
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A80119
New Gasket
Hollow
Screw
Union
BoltSST
Nozzle Leakage
No. 2 Pipe
New Gasket
SST
A79146
Check
Valve
Nozzle Leakage
No. 2 Pipe
New Gasket
A09663
:Seal Packing
±
FUEL INJECTOR ASSY (1CD±FTV)
11±63
AVENSIS REPAIR MANUAL (RM1018E)
(2) Install the bolt, the nozzle leakage No. 2 pipe and
the gasket to the cylinder head with SST.
SST 09280±00010
Torque:
8.8 N
m (90 kgf
cm, 79 in.
lbf) for bolt
21 N
m (214 kgf
cm, 15 ft
lbf) for SST
(3) Apply a light coat of soapy water (any fluid to detect
fuel leakage) on the nozzle leakage pipe No. 2 con-
nection.
(4) Using SST (turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage No.
2 pipe, and maintain 100 kPa (1.0 kgf/cm
2, 14.5 psi)
of pressure for 60 seconds to check that there are
no bubbles from the pipe connection.
SST 09992±00242
(5) After checking fuel leaks, wipe off soapy water from
the pipe connection.
(6) Remove 2 SSTs, and then remove the bolt, the nozzle leakage No.2 pipe and the gasket.
(7) Place a new gasket and reinstall the nozzle leakage No. 2 pipe with the check valve and the bolt.
Torque:
8.8 N
m (90 kgf
cm, 79 in.
lbf) for bolt
21 N
m (214 kgf
cm, 15 ft
lbf) for check valve
HINT:
Do not disassemble the check valve on the engine. (8) Reconnect the fuel hose to the nozzle leakage No.
2 pipe.
19. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head. Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
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A31032
A32639
A77414
Straight
Pin
Key
Groove
14±174
±
ENGINE MECHANICAL CAMSHAFT (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Put air pressure into the oil port with 150 kpa (1.5 kgf/cm2
21 psi), and turn the camshaft timing gear to the advance
direction (counterclockwise) by hand.
CAUTION:
Cover the paths with shop rag to avoid oil splashing.
HINT:
Depending on the air pressure, the camshaft timing gear will
turn to the advance angle side without applying force by hand.
Also, under the condition that the pressure can be hardly ap-
plied because of the air leakage from the port, there may be the
case that the lock pin could be hardly released.
(d) Remove the fringe bolt of camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If reusing the camshaft timing gear, release the
straight pin lock first, and then install the gear.
13. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET (LEADED GASOLINE) Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
14. INSTALL CAMSHAFT TIMING GEAR ASSY (UNLEADED GASOLINE)
(a) Put the camshaft timing gear and the camshaft together with the straight pin off the key groove.
(b) Turn the camshaft timing gear assembly to the left direc- tion (as shown in the illustration) while lightly pushing it to-
ward the camshaft. Push further at the position where the
pin gets into the groove.
NOTICE:
Be sure not to turn the camshaft timing gear to the retard
angle side (to the right direction).
(c) Check that there is no clearance between the gear's fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
(e) Check that the camshaft timing gear can move to the re- tard angle side (to the right direction), and is locked at the
most retarded position.
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