compression ratio TOYOTA AVENSIS 2005 Service Repair Manual

01±18
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

Confirm that the VSC warning light blinks.

VSC system will be reset when the engine is re-
started.

Fasten the vehicle with lock chains.
(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and re-
moval as it might disorder the adjustment of related
parts to VSC.
(2) Be sure to carry out the preparation for operation
and the confirmation of operation completion in ac-
cordance with the instruction of the text and when
the related operations to VSC are performed.
10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline flows into the converter, it may cause overheating and is a
fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the converter.

02±14
± PREPARATIONENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
(09962±01000)Variable Pin Wrench Arm AssyTIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
(09963±01000)Pin 10TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09992±00025Cylinder Compression Check Gauge
SetENGINE(1CD±FTV)
(09992±00121)No. 4 AttachmentENGINE(1CD±FTV)
(09992±00211)Gauge AssyENGINE(1CD±FTV)
09992±00242Turbocharger Pressure GaugeVALVE CLEARANCE(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
09992±00500Compression Gauge AttachmentENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)

± PREPARATIONENGINE MECHANICAL
02±15
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09011±12301Socket Wrench 30 mmENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09017±38120Deep Socket Wrench 12 mmPARTIAL ENGINE ASSY(1CD±FTV)
09040±00011Hexagon Wrench SetPARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
(09043±20050)Socket Hexagon Wrench 5PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
(09043±20100)Socket Hexagon Wrench 10PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09043±50100Bi±hexagon Wrench 10 mmCYLINDER HEAD GASKET(1AZ±FE)
CYLINDER HEAD
GASKET(1AZ±FSE)
09090±04020Engine Sling DevicePARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09216±00021Belt Tension GaugeENGINE(1CD±FTV)
DRIVE BELT(1CD±FTV)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
(09857±00031)Spark Plug Gap GaugeENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
Equipment
Hexagon wrench (6mm)
Feeler gauge
CO/HC meter
Compression gauge
Dial indicator
Dial indicator or dial indicator with magnetic base
Micro meter
Radiator cap tester
Straight edge
Tachometer
Torque wrench

0505L±04
05±22
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can\
not be confirmed in the basic inspection, proceed to this problem symptoms \
tables and troubleshoot accord-
ing to the numbered order given below.
SymptomSuspect AreaSee page
Engine does not crank (Does not start)1. Starter and starter relay
2. Neutral start switch circuit*19±1

No initial combustion (Does not start)
1. ECM power source circuit
2. Ignition coil (w/ Igniter) circuit
3. Fuel pump control circuit
4. Fuel system05±124
05±103
05±131
11±1
No complete combustion (Does not start)
1. Fuel pump control circuit
2. Ignition coil (w/ Igniter) circuit
3. Fuel system05±131
05±103
11±1
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Ignition coil (w/ Igniter)
5. Spark plug
6. Compression
7. Fuel system05±135
05±100
05±131
05±10318±3
14±111±1
Cold engine (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Fuel system
5. Ignition coil (w/ Igniter)
6. Spark plug05±135
05±100
05±131 11±1
05±103 18±3
Hot engine (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Fuel system
5. Ignition coil (w/ Igniter)
6. Spark plug05±135
05±100
05±131 11±1
05±103 18±3
Incorrect first idle (Poor idling)1. ISC valve circuit05±100
High engine idle speed (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Neutral start switch circuit*05±100
05±124

Low engine idle speed (Poor idling)
1. ISC valve circuit
2. Neutral start switch circuit*
3. Fuel pump control circuit
4. Fuel system05±100

05±131 11±1
Rough idling (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Fuel pump control circuit05±100
05±124
05±131
Hunting (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Fuel pump control circuit05±100
05±124
05±131
Hesitation/Poor acceleration (Poor drivability)
1. Fuel system
2. Fuel pump control circuit
3. Ignition coil (w/ Igniter) circuit11±1
05±131
05±103
Muffler explosion, after fire (Poor drivability)
1. Ignition coil (w/ Igniter) circuit
2. Spark plug
3. Fuel system05±103 18±3
11±1
Surging (Poor drivability)
1. Fuel pump control circuit
2. Spark plug
3. Fuel system05±131 18±3
11±1

± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±73
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE
DETECTED
DTC P0301 CYLINDER 1 MISFIRE DETECTED
DTC P0302 CYLINDER 2 MISFIRE DETECTED
DTC P0303 CYLINDER 3 MISFIRE DETECTED
DTC P0304 CYLINDER 4 MISFIRE DETECTED
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation of each cylinder.
The ECM counts the number of times from the engine speed change rate, indicating that misfire has oc-
curred. When the misfire rate equals to or exceeds the count, indicating that the engine condition has deteri-
orated, the CHK ENG is illuminated.
If the misfire rate is high enough and the driving conditions causes the catalyst to overheat, the CHK ENG
blinks when the misfire occurs.
HINT:

For any particular 200 revolutions of engine, misfiring which could result in overheating of catalyst is
detected. This cause CHK ENG to blink (1 trip detection logic).

For any particular 1,000 revolutions of engine, misfiring which could result in a deterioration of emis-
sions is detected. This cause CHK ENG to illuminate (2 trip detection logic).
DTC No.DTC Detecting ConditionTrouble Area
P0300Misfiring of random cylinders is detected

Open or short in engine wire

Connector connection

Vacuum hose connection

PCV hose

Ignition system
P0301
P0302Misfiring of each cylinder is detected
Ignition system

Injector

Fuel pressure

Mass air flow meter

Engine coolant temperature sensor
P0302
P0303
P0304Misfiring of each cylinder is detectedEngine coolant tem erature sensor

Compression pressure

Valve clearance

Valve timing

ECM
HINT:
When 2 or more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is re-
corded, it is indicated that the misfires were detected and recorded at different times.
05C6B±01

05C6Q±01
05±168
±
DIAGNOSTICS SFI SYSTEM(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee page
Engine does not crank (Does not start)1. Starter
2. Starter relay19±8
19±8
No initial combustion (Does not start)
1. ECM power source circuit
2. Fuel pump control circuit
3. ECM05±257
05±264 01±32
No complete combustion (Does not start)1. Fuel pump control circuit05±264
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. Fuel pump control circuit
3. Compression05±278
05±264
14±101
Cold engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuit05±278
05±264
Hot engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuit05±278
05±264
High engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit

05±257
Low engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuit

05±264
Rough idling (Poor idling)1. Compression
2. Fuel pump control circuit14±101
05±264
Hunting (Poor idling)1. ECM power source circuit
2. Fuel pump control circuit05±257
05±264
Hesitation/Poor acceleration (Poor driveability)1. Fuel pump control circuit
2. A/T faulty05±264
05±879
Surging (Poor driveability)1. Fuel pump control circuit05±264
Engine stalls soon after starting1. Fuel pump control circuit05±264
Engine stalls during A/C operation1. A/C signal circuit (Compressor circuit)
2. ECM

01±32
Unable to refuel/Difficult to refuel1. ORVR system

05CDX±01
05±320
±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
When the malfunction is not confirmed in the DTC check and the problem still\
can not be confirmed in the
basic inspection either, proceed to this problem symptoms table and troubleshoot according to the number
given below.
SymptomSuspected AreaSee page
Engine does not crank (Does not start)
2. Starter
3. Starter relay
4. Park/neutral position switch19±10
19±10 40±8
No initial combustion (Does not start)
1. ECM power source circuit
2. Ignition coil assy
3. Fuel pump control circuit
4. Injector circuit05±502
05±439
05±507
05±415
No complete combustion (Does not start)
1. Ignition coil assy
2. Fuel pump control circuit
3. Injector circuit05±439
05±507
05±415
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. Ignition coil assy
3. Spark plug
4. Compression
5. Injector circuit
6. Fuel pump control circuit05±513
05±43918±14
14±181
05±415
05±507
Cold engine (Difficult to start)
1. Starter signal circuit
2. Injector circuit
3. Ignition coil assy
4. Spark plug
5. Fuel pump control circuit05±513
05±415
05±439 18±14
05±507
Hot engine (Difficult to start)
1. Starter signal circuit
2. Injector circuit
3. Ignition coil assy
4. Spark plug
5. Fuel pump control circuit05±513
05±415
05±439
18±14
05±507
High engine idle speed (Poor idling)
1. ECM power source circuit
2. Park/neutral position switch
3. Back up power source circuit05±502
40±8
05±467
Low engine idle speed (Poor idling)
1. Park/neutral position switch
2. Injector circuit
3. Back up power source circuit
4. Fuel pump control circuit40±8
05±415
05±467
05±507
Rough idling (Poor idling)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. Injector circuit
4. Fuel pump control circuit
5. Ignition coil assy
6. Compression
7. Back up power source circuit05±336
05±342
05±415
05±507
05±439
14±181
05±467
Hunting (Poor idling)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. ECM power source circuit05±336
05±342
05±502
Hesitation/Poor acceleration (Poor driveability)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. Injector circuit
4. Ignition coil assy
5. Fuel pump control circuit05±336
05±342
05±415
05±439
05±507
Muffler explosion after fire (Poor driveability)
1. Ignition coil assy
2. Spark plug
3. Injector circuit05±439 18±14
05±415

05±552
±
DIAGNOSTICS ECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
Lower engine idle speed (Poor idling)
1. A/C signal circuit
2. Injector
3. EGR system
4. Compression
5. Valve clearance
6. Fuel line (Air bleed)
7. EC


8. Supply pump
9. Fuel pressure sensor
10.Diesel throttle55±3
11±56
12±16
14±266
14±270 ±
10±56
10±56
10±56
10±56
Rough idling (Poor idling)
1. Injector
2. Fuel line (Air bleed)
3. EGR system
4. Compression
5. Valve clearance
6. EC

7. Supply pump
8. Fuel pressure sensor
9. Diesel throttle11±56 ±
12±16
14±266
14±270 10±56
10±56
10±56
10±56
Hunting at hot engine (Poor idling)
1. Injector
2. EC
power source circuit
3. Compression
4. Fuel line (Air bleed)
5. Valve clearance
6. EC

7. Supply pump
8. Fuel pressure sensor
9. Diesel throttle11±56
05±686
14±266 ±
14±270
10±56
10±56
10±56
10±56
Hunting at cold engine (Poor idling)
1. Injector
2. EC
power source circuit
3. Compression
4. Fuel line (Air bleed)
5. Valve clearance
6. EC

7. Supply pump
8. Fuel pressure sensor
9. Diesel throttle11±56
05±686
14±266 ±
14±270
10±56
10±56
10±56
10±56
Hesitation/ Poor acceleration (Poor driveability)
1. Injector
2. Fuel filter
3. EGR system
4. Compression
5. EC

6. Supply pump
7. Fuel pressure sensor
8. Diesel throttle11±56
11±82
12±16
14±266 10±56
10±56
10±56
10±56
Knocking (Poor driveability)
1. Injector
2. EGR system
3. EC

4. Supply pump
5. Fuel pressure sensor11±56
12±16
10±56
10±56
10±56
Black smoke (Poor driveability)
1. Injector
2. EGR system
3. EC

4. Supply pump
5. Fuel pressure sensor
6. Diesel throttle11±56
12±16
10±56
10±56
10±56
10±56

A79149
SST
30 cm
(11.81 in.)
11±74
±
FUEL INJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
46.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the injection pump replaced, must
replace the fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a)Temporarily install the fuel inlet pipe.
(b)Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c)Using SST, tighten the nut of the fuel inlet pipe to the injec-
tion pump side.
SST09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
47.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
48.INSTALL TIMING BELT(See page 14±307)
49.CHECK VALVE TIMING(See page 14±307)
50.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
51. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Torque:
37 N
m (375 kgf
cm, 27 ft
lbf) for 14mm head bolt
64 N
m (650 kgf
cm, 47 ft
lbf) for 17mm head bolt

110UE±01
A78267
Rear Seat Cushion Assy
Rear Floor Service Hole Cover
Fuel Pump Gauge Retainer
Fuel and Evaporation Vent Tube Sub±assy
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Fuel Suction Tube Set Gasket

Gasket
Gasket Exhaust Pipe Assy Front
Compression Spring
Floor Panel
Brace FrontCompression
Spring43 (440, 32)
30 (302, 22)
43 (440, 32)
± FUELFUEL TANK ASSY (DIESEL)
11±101
AVENSIS REPAIR MANUAL (RM1018E)
FUEL TANK ASSY (DIESEL)
COMPONENTS