service TOYOTA AVENSIS 2003 Service Repair Manual

010B6±13
±
INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±21
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
There are many ECU controlled systems used in the AVENSIS. In general, ECU controlled system are con-
sidered to be very intricate and require a high level of technical knowledge an\
d expert skill to troubleshoot.
The fact is, however, that if you proceed by inspecting the circuits one by one, troubleshoo\
ting of these sys-
tems is not complex. If you have adequate understanding of the system and ba\
sic knowledge of electricity,
the problem can be accurately diagnosed and fixed. This manual is design\
ed based on the above principle
to help service technicians perform accurate and effective troubleshooting, and is compiled for the following
major ECU controlled systems:
The troubleshooting procedures are described on the following pages.
SystemPage
1. SFI System [1ZZ±FE, 3ZZ±FE]05±1
2. SFI System [1AZ±FE]05±143
3. SFI System [1AZ±FSE]05±290
4. ECD System [1CD±FTV]05±523
5. ABS with EBD System05±696
6. ABS with EBD & BA & TRC & VSC System05±752
7. Electronic Controlled Automatic Transmission [ECT] [U241 (1AZ±FE)]05±856
8. Electronic Controlled Automatic Transmission [ECT] [U241 (1AZ±FSE)]05±915
9. Electronic Controlled Automatic Transmission [ECT] [U341]05±980
10.Electronic Motor Power Steering System05±1042
11. Air Conditioning System05±1088
12.Combustion Type Power Heater System05±1161
13.Supplemental Restraint System05±1181
14.Audio System05±1393
15.Navigation System05±1435
16.Combination Meter05±1497
17.Power Door Lock Control System05±1534
18.Wireless Door Lock Control System05±1568
19.Key Reminder Warning System05±1586
20.Engine Immobiliser System05±1599
21.Theft Deterrent System05±1627
22.Multiplex Communication System05±1654
23.Cruise Control System05±1697
FOR USING HAND±HELD TESTER

Before using the tester, the tester's operator manual should be read thoroughly.

If the tester cannot communicate with the ECU controlled systems when you \
have connected the cable
of tester to the DLC3, turned the ignition switch ON and operated the test\
er, there is a problem on the
vehicle side or tester side.
(1) If the communication is normal when the tester is connected to another veh\
icle, inspect the diag-
nosis data link line (Bus
line) or ECU power circuit of the vehicle.
(2) If the communication is still impossible when the tester is connected to a\
nother vehicle, the prob- lem is probably in the tester itself, so perform the Self Test procedures outlined in the Tester Oper-
ator 's Manual.
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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)
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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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Illustration:what to do and where
Component part No.
Detailed text: how to perform task
Task heading: what to do
Set part No
D31009
01±2
±
INTRODUCTION HOW TO USE THIS MANUAL
AVENSIS REPAIR MANUAL (RM1018E)
(c) Tightening torque, grease application area, and non±reusable parts are described as important points in the procedures.
NOTICE:
There are cases where such information can only be explained by using an illu\
stration. In these
cases, all the information such as torque, oil, etc. are described in the illu\
stration.
(d) Installing procedures are performed in the reverse order of the removal and only the important points are described.
(e) 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
notices are placed.
(f) There may be a case where the illustrations of similar models are used. In th\
at case, specific details may be different from the actual vehicle.
(g) 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 explanation text tells how to perform the task and gives other information such as specifica-tions and 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 deta\
iled information. Important
specifications and warnings always are written in bold type to stand out from the rest\
of the text.
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 quick reference.
6. TERMS DEFINITION
CAUTIONIndicates the possibility of injury to you or other people.
NOTICEIndicates the possibility of damage to the components being repaired.
HINTProvides additional information to help you to perform the repair efficiently.
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L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
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INTRODUCTIONREPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE (1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.
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01±40
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E) Abbreviations Meaning
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
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
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INTRODUCTION TERMS
01±43
AVENSIS REPAIR MANUAL (RM1018E)
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
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022L4±02
02±36
±
PREPARATION AUTOMATIC TRANSMISSION / TRANS
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetTRANSMISSION CONTROL CABLE
ASSY
(07117±58060)Refrigerant Drain Service ValveTRANSMISSION CONTROL CABLE
ASSY
(07117±58070)T±JointTRANSMISSION CONTROL CABLE
ASSY
(07117±58080)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±58090)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±78050)Refrigerant Charging GaugeTRANSMISSION CONTROL CABLE
ASSY
(07117±88060)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88070)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88080)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
09023±12700Union Nut Wrench 17mmAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09308±00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09316±60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U241E)
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022J5±01
±
PREPARATION ENGINE CONTROL SYSTEM
02±3
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE CONTROL SYSTEM
PREPARATION
SST
09268±21010Fuel Hose PullerKNOCK SENSOR(1AZ±FE)
Recomended Tools
09082±00040TOYOTA Electrical TesterSFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetSFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
Equipment
Ohmmeter
Radiator cap tester
Service Wire Harness
Torque wrench
Vernier calipers
Voltmeter
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02±6
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PREPARATION FUEL
AVENSIS REPAIR MANUAL (RM1018E)
09082±00040TOYOTA Electrical TesterFUEL SYSTEM(1CD±FTV)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1AZ±FSE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09130±00150Water Pump PliersFUEL FILTER ASSY(1CD±FTV)
09216±00021Belt Tension GaugeINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
Equipment
Clip
Hexagon wrench (6 mm)
Measuring Flask
Ohmmeter
Radiator cap tester
Service Wire Harness
Stopwatch
Torque wrench
Vernier calipers
Wooden block
SSM
08826±00080Seal Packing Black or equivalent
(FIPG)INJECTOR ASSY(1CD±FTV)
08850±00065Butyl Tape SetFUEL TANK ASSY(DIESEL)
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022KJ±01
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PREPARATION HEATER & AIR CONDITIONER
02±47
AVENSIS REPAIR MANUAL (RM1018E)
HEATER & AIR CONDITIONER
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±58060)Refrigerant Drain Service ValveREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±58070)T±JointREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
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