stop start TOYOTA AVENSIS 2003 Service Repair Manual

IN0383
ExampleGround
IN0384
Ground
ECU Side
W/H Side
Ground
01±36±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
4. CHECK AND REPLACE ECU
NOTICE:

Start an inspection of the connector from the back-
side of the connector on the wire harness side with
the connector connected to the ECU.

When no measurement condition is specified, per-
form the inspection with the engine stopped and also
the ignition switch ON.
(a) First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. In this case, re-
place the ECU with one that functions normally and check
if the symptoms appear.
(1) Measure the resistance between the ECU groundterminal and body ground.
Resistance: 1
or less
(2) Disconnect the ECU connector, check the ground terminals on the ECU side and wire harness side for
bends and check the contact pressure.
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030L2±04
03±56
±
SERVICE SPECIFICATIONS CLUTCH
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Clutch pedal support x Stopper bolt2525018
Clutch pedal sub±assy x Clutch pedal support3737527
Clutch pedal support x Body1919514
Clutch pedal support x Clutch start switch assy1616012
Clutch master cylinder push rod clevis lock nut121209
Clutch master cylinder x Flexible hose tube1515511
Clutch master cylinder x Body121209
Clutch release cylinder bleeder plug8.48574 in.
lbf
Clutch release cylinder x Transaxle housing
1CD±FTV/1AZ±FSE/1AZ±FE engine type
121209
Clutch release cylinder x Transaxle housing 1ZZ±FE/3ZZ±FE engine type1414110
Clutch release cylinder x Flexible hose tube bracket 1ZZ±FE/3ZZ±FE engine type
5.05144 in.
lbf
Clutch release cylinder x Clutch line clamp 1AZ±FSE/1AZ±FE engine type121229
Clutch release cylinder x Flexible hose tube1515511
Clutch release cylinder x Clutch accumulator assy 1CD±FTV engine type121209
Clutch accumulator assy x Flexible hose tube 1CD±FTV engine type1515511
Clutch cover assy x Flywheel sub±assy1919514
Release fork support x Transaxle assy 1AZ±FSE/1AZ±FE engine type
1ZZ±FE/3ZZ±FE/1CD±FTV engine type48
37480
37535
27
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±20
±
FUEL FUEL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand±held tester (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine. (3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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110UW±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUELFUEL SYSTEM(1AZ±FE)
11±15
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2)Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±6
±
FUEL FUEL SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf/cm
2, 44 to 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND FUEL LEAK
(a) When using the hand±held tester (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine. (3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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110UT±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUELFUEL SYSTEM(1ZZ±FE/3ZZ±FE)
11±1
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec-
tion to catch any fuel that may spill.
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No.1 Fuel Pipe
Fuel Tube Connector
SST
(Clip)
SST (T joint)SST
SST
(Hose)
B12975
11±34
±
FUEL FUEL SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(g) Install SST (pressure gauge) and a fuel tube connector using SST as shown in the illustration.
SST 09268±41047(95336±08070),09268±45014 (09268±41250, 09268±41200, 09268±41220)
(h) Wipe up any gasoline.
(i) Reconnect the negative (±) battery cable.
(j) Connect the hand±hand tester to the DLC3.
(k) Measure the fuel pressure. Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check the fuel hoses connections, the fuel
pump, the fuel filter and the fuel pressure regulator.
(l) Disconnect the hand±held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle. Fuel pressure:
196 to 588 kPa (2 to 6 kgf/cm
2, 28 to 85 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.
Fuel pressure:147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, the pres-
sure regulator and/or the injectors.
(q) After checking the fuel pressure, disconnect the negative (±) battery cable and carefully remove SST and the fuel
tube connector to prevent gasoline from splashing.
(r) Reconnect the No. 1 fuel pipe (fuel tube connector).
CAUTION:
After taking the precautions, connect the fuel tube con-
necter (quick type).
2. CHECK FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS
(a) When using the hand±held tester
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and the hand±held tes-ter main switch ON.
NOTICE:
Do not start the engine.
(3) Select the active test mode on the hand±held tester.
(4) Perform the active test. Check that the fuel pumpoperates and check for fuel leaks.
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A75340
Battery4
5

B12608
A76859
Hand±held Tester
±
FUEL FUEL SYSTEM (1AZ±FSE)
11±35
AVENSIS REPAIR MANUAL (RM1018E)
(b) When not using the hand±held tester
(1) Connect the positive (+) lead form the battery to ter-minal 4 of the connector and connect the negative
(±) lead to terminal 5.
(2) Check that the pump operates.
3. CHECK FUEL PUMP OPERATION (HIGH PRESSURE)
(a) Remove the No. 1 engine cover.
(b) Start the engine.
(c) Using a sound scope, hear the operating sound of the pump.
If there is no sound, replace the pump.
(d) Stop the engine.
(e) Reinstall the engine cover.
4. CHECK FUEL HIGH PRESSURE
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine.
(c) Select the active test mode on the hand±held tester.
(d) Perform the active test check the fuel high pressure at idle to 3,000 rpm.
Fuel high pressure:
9.5 to 10.5 Mpa (97 to 107 kgf/cm
2, 1,380 to 1,520 psi)
If the pressure is not as specified, check the fuel pump, high
pressure fuel pump, fuel pressure sensor, wiring and fuel leak-
age.
(e) Stop the engine.
(f) Disconnect the hand±held tester.
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110UZ±01
A75339
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
11±30
±
FUELFUEL SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FSE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts. 2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.
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±
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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