check engine light TOYOTA AVENSIS 2005 Service Repair Manual

A87894
AF− AF+
A34
Front View
Component Side
(w/ Headlight Beam Level Control):
1
2
3
4
HT
+B
A/F Sensor
Connector
A87894
AF−
AF+
A34
Front View
HT +B
1
2
3
4
Component Side
(w/o Headlight Beam Level Control):
A/F Sensor
Connector
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −485
AVENSIS Supplement (RM 1045E)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using the hand−held tester. Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was
running or stopped, if the engine was warmed up or not, if the air −fuel ratio was lean or rich, and other data
from the time the malfunction occurred.
1 CHECK OTHER DTC(IN ADDITION TO P2237)
(a) Connect the hand −held tester to the DLC3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Select the item ”DIAGNOSIS / OBD/MOBD / DTC INFO / CURRENT CODES”.
(d) Read DTCs.
Result:
Display (DTC output)Proceed to
P2237 and P2238 and/or P2239A
P2237B
B REPLACE ECM (See page 10− 29)
A
2 INSPECT AIR FUEL RATIO SENSOR(RESISTANCE)
(a) Disconnect the A34 A/F sensor connector.
(b) Measure the resistance between the terminals of the A/F sensor.
Resistance (w/ Headlight beam level control):
Tester ConnectionSpecified Condition
HT (1) − +B (2)0.86 to 1.1
at 20 _C (68 _F)
Resistance (w/o Headlight beam level control):
Tester ConnectionSpecified Condition
HT (2) −+B ( 1)0.86 to 1.1
at 20 _C (68 _F)
(c) Reconnect the A/F sensor connector.
NG REPLACE AIR FUEL RATIO SENSOR
OK

G23400G29214
Accelerator Pedal
Opening Angle
Lock−up OFF
Lock−up ON

time Engine Speed
Accelerator Pedal
Fully Released
− DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U151E)05−583
AVENSIS Supplement (RM1045E)
INSPECTION PROCEDURE
HINT:
Performing the ACTIVE TEST using the hand−held tester allows the relay, VSV, actuator and so on to oper-
ate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method
to shorten labor time.
It is possible to display the DATA LIST during the ACTIVE TEST.
(a) Warm up the engine.
(b) Turn the ignition switch off.
(c) Connect the hand−held tester to the DLC3.
(d) Turn the ignition switch to the ON position.
(e) Push the ”ON” button of the hand−held tester.
(f) Select the item ”DIAGNOSIS / OBD/MOBD / ACTIVE TEST”.
(g) According to the display on tester, perform the ”ACTIVE TEST”.
ItemTest DetailsDiagnostic Note
LOCK UP
[Test Details]
Control the shift solenoid DSL to set the automatic transaxle to the
lock−up condition.
[Vehicle Condition]
Vehicle Speed: 60 km/h (37 mph) or more
Possible to check the DSL opera-
tion.
HINT:
SThis test can be conducted when the vehicle speed is 60 km/h (37 mph) or more.
SThis test can be conducted with the 5th gear.
(h) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.
HINT:
SWhen changing the accelerator pedal opening angle while driving, if the engine speed does not
change, lock−up is on.
SSlowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will
close the throttle valve and lock−up may be turned off.)

05JLB−01
G23403
Hand −Held Tester
DLC3
−
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U 151E)05 −553
AVENSIS Supplement (RM 1045E)
DIAGNOSIS SYSTEM
1. DESCRIPTION for EURO −OBD (European spec.)
S When troubleshooting Euro −OBD vehicles, the only dif-
ference from the usual troubleshooting procedure is that
you c onnect an O BD scan t ool com plying wit h I SO
1 503 1− 4 or a hand −held tester to the vehicle, and read
the various data output from the vehicle’s ECM.
S Eur o −O BD r egulat ions r equir e t hat t he v ehicle’s on −
board computer illuminates the check engine warning
light (CHK ENG (MIL)) on the instrument panel when the
computer detects a malfunction in: 1) the emission control
system / components, or 2) the powertrain control compo-
nents (which affect vehicle emissions), or 3) the comput-
er. In addition, the applicable Diagnostic Trouble Codes
(DTCs) prescribed by ISO 1503 1− 4 are recorded in the
ECM memory (see page 05 −564).
If the malfunction does not reoccur in 3 consecutive trips, the
CHK ENG (MIL) goes off automatically but the DTCs remain re-
corded in the ECM memory.
S To check the DTCs, connect the OBD scan tool or hand −
held tester to Data Link Connector 3 (DLC3) on the ve-
hicle. The OBD scan tool or hand −held tester also en-
ables you to erase the DTCs and check the freeze frame
data and various forms of engine data. (See the instruc-
tion manual for the OBD scan tool or the hand −held tes-
ter).
S DTCs include ISO controlled codes and manufacturer
controlled codes. ISO controlled codes must be set ac-
cording to the ISO, while manufacturer controlled codes
can be set by a manufacturer within certain restrictions
(see the DTC chart on page 05 −564).
S The diagnosis system operates in normal mode during
normal vehicle use. In ”normal mode”, 2 trip detection log-
ic* is used to ensure accurate detection of malfunctions.
A ”check mode”, is also available to technicians as an op-
tion. In ”check mode”, 1 trip detection logic is used for sim-
ulating malfunction symptoms and increasing the sys-
tem’s ability to detect malfunctions, including intermittent
malfunctions (hand −held tester only)
(see page 05 −557).
S*2 trip detection logic:
When a malfunction is first detected, the malfunction is
temporarily stored in the ECM memory ( 1st trip). If the
ignition switch is turned OFF and then ON again, and the
same malfunction is detected again, the CHK ENG (MIL)
will illuminate (2nd trip).

056IN−05
−
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U 151E)05 −545
AVENSIS Supplement (RM 1045E)
PROBLEM SYMPTOMS TABLE
HINT:
If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check
the electrical circuits for each symptom in the order given in the charts on the following pages and proceed
to the page given for troubleshooting.
The Matrix Chart is divided into 2 chapters.
1. Chapter 1: Electronic Circuit Matrix Chart
S Refer to the table below when the trouble cause is considered to be electrical.
S If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart
of each circuit, proceed to the circuit with the next highest number in the table to continue the check.
S If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and
replace the ECM.
HINT:
* 1 : When the circuit on which mark * 1 is attached is a malfunction, DTC could be output (see page 05 −564).
*2: LHD
SymptomSuspect AreaSee page
No down −shift
(A particular gear, from 1st to 4th gear, is not down −shifted)
1. Shift solenoid valve (SL 1) circuit*1
2. Shift solenoid valve (SL2) circuit*1
3. Shift solenoid valve (SL3) circuit*1
4. Shift solenoid valve (SR) circuit*1
5. ECM
05 −589
05 −60 1
05 −61 0
05 −598
0 1− 32
No down −shift (5th
4th)
1. Park/neutral position switch circuit *1
2. Shift solenoid valve (S4) circuit*1
3. ECM
05 −566
05 −595
0 1− 32
No up −shift
(A particular gear, from 1st to 4th gear, is not up −shifted)1. Shift solenoid valve (SL 1) circuit*1
2. Shift solenoid valve (SL2) circuit*1
3. ECM
05 −589
05 −60 1
0 1− 32
No up −shift (4th
5th)
1. Park/neutral position switch circuit *1
2. Shift solenoid valve (S4) circuit*1
3. ECM
05 −566
05 −595
0 1− 32
No lock −up
1. Shift solenoid valve (DSL) circuit*1
2. Stop light switch circuit*1
3. Engine coolant temp. sensor circuit*1
4. ECM
05 −582
05 −580
05 −31
0 1− 32
No lock −up off1. Shift solenoid valve (DSL) circuit*1
2. ECM
05 −582
0 1− 32
Shift point too high or too low
1. Throttle position sensor circuit*1
2. Shift solenoid valve (SLT) circuit*1
3. ECM
05 −31
05 −622
0 1− 32
Up −shift to 5th from 4th while engine is cold1. Engine coolant temp. sensor circuit*1
2. ECM
05 −31
0 1− 32
No gear change by shifting into ”+” or ” −” while the shift lever is in
the S position1 . Transmission control switch circuit
2. ECM05 −625
0 1− 32
Harsh engagement (N
D)1. Shift solenoid valve (SL 1) circuit*1
2. ECM
05 −589
0 1− 32
Harsh engagement (Lock −up)1. Shift solenoid valve (SL2) circuit*1
2. ECM
05 −60 1
0 1− 32
Harsh engagement (Any driving position)1. Shift solenoid valve (SLT) circuit*1
2. ECM
05 −622
0 1− 32
Poor acceleration1. Shift solenoid valve (SLT) circuit*1
2. ECM
05 −622
0 1− 32

A66060
E12
ECM Connector
E1
LUSL
A92422
Signal Waveform
10 msec./Dvision
10
−20
−
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(4) When turning the accelerator pedal position sensor lever t o t he f ull − open posit ion, check t hat t he
t hr ot t le v alve opening per cent age ( THRO TTLE
POS) of DATA LIST shows the standard value.
Standard throttle valve opening percentage:
60 % or higher
If the operation is not as specified, check the accelerator pedal
position sensor (see page 10 −22), wiring and ECM.
(c) If you have no hand −held tester:
(1) Inspect the throttle position sensor using a oscillo- scope.
(2) During idling, check the waveform between the spe- cified terminals of the E12 ECM connectors.
Standard:
Tester ConnectionSpecified Condition
LUSL (E12 −4) − E1 (E12 −7)Correct waveform is as shown on the left
If the operation is not as specified, check the accelerator pedal
position sensor (see page 10 −22), wiring and ECM.
(d) Inspect the air assist system.
(1) Start the engine, then check that the check engine warning light does not light up.
(2) Allow the engine to warm up to the normal operating
temperature.
(3) Turn the A/C compressor ON to OFF, then check the
idle speed (see page 14 −87).
Idle speed (transmission in neutral): 800 á50 rpm
If the result is not as specified, check the wiring and ECM.
NOTICE:
Perform the inspection under condition without electrical
load.
(e) After taking the above steps (b) to (c), perform the driving test.
(f) Check that there is no sense of incongruity.

A61190
90_ 90
_
90_90
_ 90
_
90_
Paint Mark
Front
A85427
TDC Mark
Dot Mark
90 _
A85942
New O −ring
14 −172−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 _ in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by an additional 90 _ in
the same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional
90_ in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man-
ifold side.
82. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing gear at the position
of 90_ BTDC.
NOTICE:
If the timing belt is disengaged, the crankshaft timing gear
placed at wrong angle can cause contact of the piston head
with the valve head.
83. INSTALL CAMSHAFT (See page 14 −151)
84. INSTALL NO.2 CAMSHAFT (See page 14 −151)
85. REMOVE CAMSHAFT OIL SEAL (See page 14 −151)
86. INSTALL CAMSHAFT OIL SEAL (See page 14 −151)
SST 09223 −46011
87. INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14 −151)
88. I NSTALL EXHAUST F UEL ADDI TI O N I NJECTO R ASSY
(a) Install a new gasket to the cylinder head.
(b) Install a new O −ring to the injector.
(c) Apply a light coat of engine oil to the O −ring on the injec-
tor.
(d) Install the addition injector and nozzle holder clamp.
(e) Using a Torx socket wrench (T40), install the Torx screw. Torque: 12 N
m (117 kgf
cm, 8.5 ft
lbf)
NOTICE:
Be careful that the tools do not interfere with the resin part
when installing.
89. INSTALL CAMSHAFT TIMING PULLEY (See page 14 −151)
SST 09960 −10010 (09962 −01000, 09963 −01000)
90. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
91. INSTALL INJECTOR ASSY (See page 11 −46)
92. INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 14 −151)
SST 09992 −00242

A85428
Seal Width
2to4mm
(0.08 to 0.16 in.)Seal Packing
A62592
SST
A85760
90_
14
−156
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826 −00080 or equivalent
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing.
(3) Immediately remove the nozzle from the tube, then reinstall the cap.
(c) Install the oil seal retainer with the 4 bolts. Tighten the 4 bolts uniformly in several steps.
Torque: 9.8 N
m (100 kgf
cm, 7.2 ft
lbf)
52. INSTALL CAMSHAFT TIMING PULLEY
(a) Install the pulley set key to the groove of the camshaft.
(b) Align the keyway of the timing pulley with the key located on the camshaft, then slide the pulley into place.
(c) Using SST, install the pulley bolt. SST 09960 −10010 (09962 −01000, 09963 −01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
53. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
54. INSTALL INJECTOR ASSY 55. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Remove the bolt which is tightened at the center of thecamshaft bearing cap No. 4.
(b) Install the nozzle leakage pipe and 4 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint of the gasket
comes within the ranges shown in the illustration.
(c) Apply a light coat of engine oil to the 4 hollow screws and bolt.
(d) Tighten the 4 hollow screws and bolt by hand.
(e) Tighten the 4 hollow screws and bolt. Torque:
16 N
m (163 kgf
cm, 12 ft
lbf) for hollow screw
20 N
m (204 kgf
cm, 15 ft
lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(f) Check that there are no leaks from the nozzle leakage pipe connection.

A86430
New GasketHollow
Screw
SST
A09663
:Seal Packing
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
14 −157
AVENSIS Supplement (RM1045E)
(1) Apply a light coat of soapy water (any fluid to detect
fuel leakage) to the nozzle leakage pipe connec-
tion.
(2) Using SST (a turbocharger pressure gauge), attach SST to the fuel return side of the nozzle leakage
pipe, then 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
(3) After checking fuel leaks, wipe off soapy water from the pipe connection.
56. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as illustrated. 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)
57. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
58. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
59. INSTALL VACUUM PUMP ASSY (See page 14 −108)
60. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold at room temperature.
(a) Install the 2 lower injection pipe clamps to the intake man-
ifold.
(b) Remove the vinyl or plastic bag from the injector and the
vinyl tape from the common rail.
(c) Temporarily install the injection pipe.

A77437
Cylinder Head
Cylinder Block
Seal Packing
Cylinder
Head Gasket
2.5 to 3 mm
1.25 to 1.5 mm
A7741012
3 4
109 85
67
A00976A77411
90_
Engine
Front
Paint Mark
A83497
14−82
− ENGINE MECHANICALCYLINDER HEAD GASKET (2AZ−FSE)
AVENSIS Supplement (RM1045E)
63. INSTALL CYLINDER HEAD SUB−ASSY
HINT:
The cylinder head set bolts are tightened in the 2 successive
steps.
(a) Apply a continuous bead (Diameter 2.5 to 3 mm (0.098 to
0.118 in.)) of seal packing as shown in the illustration.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
SRemove any oil from contact surface.
SInstall the cylinder head within 3 minutes after apply-
ing seal packing.
SAfter installing the cylinder head, cylinder head bolts
must be tightened within 15 minutes.
SDo not start the engine within 2 hours of installation.
(b) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(c) Install bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
(d) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm bi−hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 79 N
m (806 kgf
cm, 58 ft
lbf)
(e) Mark the front side of the cylinder head set bolts with
paint.
(f) Retighten the cylinder head set bolts by 90_in the same
sequence as a step (d).
(g) Check that each paint mark is now at a 90_angle to the
front.
(h) Install the camshaft housing plug as shown in the illustra-
tion.

190V6−01
Z11580A80938A82936
Type A:
Type B:
BlueWhite
Red Green DarkClear or
light yellow
B00543
B00540
19−6
− STARTING & CHARGINGCHARGING SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM1045E)
ON−VEHICLE INSPECTION
1. INSPECT BATTERY (EXCEPT MAINTENANCE−FREE
BATTERY)
(a) Check the battery electrolyte level.
(1) Check the electrolyte quantity of each cell.
If the electrolyte quantity is below the recommended amount,
add distilled water.
(b) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
2. INSPECT BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Visually check the battery terminals.
(1) Check that the battery terminals are not loosened or corroded.
(b) Visually check the fusible link and fuses.
(1) Check that there is continuity of the fusible links, high−current fuses and regular fuses.
3. INSPECT V−RIBBED BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
SIf any defects are found, replace the v−ribbed belt.
SCracks on the rib side of the belt are considered ac-
ceptable.
If the belt has chunks missing from the ribs, it should
be replaced.
(b) Check that the belt fits properly in the ribbed grooves.
Confirm that the belt has not slipped out of the groove on the
bottom of the pulley by hand.
4. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that no abnormal noise is heard from the generator while the engine is running.
6. INSPECT CHARGE WARNING LIGHT CIRCUIT