TOYOTA AVENSIS 2005 Service Repair Manual

A79441
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Gasket

Gasket
Gasket
20 (204, 15)
20 (204, 15)
20 (204, 15)
12 (122, 8.9)
53 (540, 39)
13 (135, 9.7)
36 (367, 27)
61 (622, 45)
56 (571, 41)
25 (255, 18)
Turbo Insulator No. 1
Exhaust Manifold Heat Insulator No. 2
Turbocharger Stay
Turbocharger Sub±assy
Turbo Oil Inlet Pipe
Sub±assy
Manifold Stay Manifold Stay No. 2
Exhaust Manifold
Converter Sub±assy Turbo Insulator No. 2
Turbo Water Pipe
Sub±assy No. 1
13 (135, 9.7)
56 (571, 41)
Turbo Water
Hose No. 2
Turbo Water
Hose No. 1

Gasket
12 (122, 8.9)

13±10
± INTAKETURBOCHARGER SUB±ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)

13030±02
A60591
A60592
A60593
Air
E
G
A60594
Air
Filter
Battery E
± INTAKETURBO CHARGER SYSTEM (1CD±FTV)
13±7
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. VACUUM SWITCHING VALVE ASSY NO.1
(a) Inspect VSV for open circuit.
(1) Using an ohmmeter, check that the there is continu-
ity between the terminals.
Resistance: 37 ± 44
at 20
C (68
F)
(b) Inspect VSV for ground.
(1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
Specified condition: No continuity
(c) Inspect VSV operation.
(1) Check that air flows from port E to G.
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to filter.

1302Z±03
A77123
SST
A60595E2 VC
± INTAKETURBO CHARGER SYSTEM (1CD±FTV)
13±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
(a) Check for leakage or clogging between the air cleaner
housing and turbocharger inlet and between the turbo-
charger outlet and cylinder head.
(1) Clogged air cleaner...Clean or replace element
(2) Hoses collapsed or deformed...Repair or replace
(3) Leakage from connections...Check each connec-
tion and repair
(4) Cracks in components...Check and replace
2. INSPECT EXHAUST SYSTEM
(a) Check for leakage or clogging between the cylinder head
and turbocharger inlet and between the turbocharger out-
let and exhaust pipe.
(1) Deformed components...Repair or replace
(2) Foreign material in passages...Remove
(3) Leakage from components...Repair or replace
(4) Cracks in components...Check and replace
3. CHECK TURBOCHARGING PRESSURE
(a) Warm up the engine.
(b) Using a 3±way connector, connect SST (turbocharger
pressure gauge) to the hose leading to the intake air con-
nector.
SST 09992 ± 00242
(c) While depressing the clutch pedal, press the accelerator
pedal down to the full. Measure the turbocharging pres-
sure at maximum speed (5,100 to 5,250 rpm).
Standard pressure:
15 to 45 kPa (0.15 to 0.46 kgf/cm
2, 2.2 to 6.5 psi)
If the pressure is less than specification, check both the intake
air and exhaust systems for leakage.
If there is no leakage, check if the actuator hose has discon-
nected. If not, check the turbocharger.
If the pressure is greater than specification, check if the actua-
tor hose has disconnected or cracked. If not, check the turbo-
charger.
4. INSPECT TURBO PRESSURE SENSOR
(a) Inspect power source voltage
(1) Disconnect the turbo pressure sensor connector.
(2) Turn the ignition switch ON.
(3) Using a voltmeter, measure the voltage between
connector terminals 3 (VC) and 1 (E2) of the wiring
harness side.
Voltage: 4.5 to 5.5 V
(4) Turn the ignition switch OFF.
(5) Reconnect the turbo pressure sensor connector.

A79448
PIM (+)
E2 (±)ECM
Vacuum SST
A77125
SST
Pressure
13±6
± INTAKETURBO CHARGER SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Inspect supply power
(1) Turn the ignition switch ON.
(2) Disconnect the vacuum hose from the turbo pres-
sure sensor.
(3) Connect a voltmeter to terminals 35 (PIM) and 28
(E2) of the ECM and measure the output voltage
under atmospheric pressure.
(4) Apply vacuum to the turbo pressure sensor in 13.3
kPa (100 mmHg, 3.94 in.Hg) segments to 66.7 kPa
(500 mmHg, 19.96 in.Hg).
(5) Measure the voltage decrease from step (3) above
for each segment.
Voltage drop:
Apply Vacuum
[kPa (mmHg, in.Hg)]Voltage Decrease
[V]
13.3 (100, 3.94)0.1 to 0.3
26.7 (200, 7.87)0.3 to 0.5
40.0 (300, 11.81)0.5 to 0.7
57.3 (400, 15.75)0.7 to 0.9
66.7 (500, 19.96)0.9 to 1.0
(6) Using SST (turbocharger pressure gauge), apply
pressure to the turbo pressure sensor in 19.6 kPa
(0.20 kgf/cm
2, 2.84 psi) segments to 98.0 kPa (1.00
kgf/cm
2, 14.2 psi).
SST 09992±00242
(7) Measure the voltage increase from step (3) above
for each segment.
Voltage up:
Applied Pressure
[kPa (kgf/cm2, psi)]
Voltage Increase
[V]
19.6 (0.20, 2.84)0.1 to 0.4
39.2 (0.40, 5.69)0.4 to 0.7
58.8 (0.60, 8.53)0.7 to 1.0
78.5 (0.80, 11.4)1.0 to 1.3
98.0 (1.00, 14.2)1.3 to 1.6

1302Y±03
A77119
A77120
A77121
± INTAKETURBO CHARGER SYSTEM (1CD±FTV)
13±3
AVENSIS REPAIR MANUAL (RM1018E)
TURBO CHARGER SYSTEM (1CD±FTV)
PRECAUTION
1. MAINTENANCE PRECAUTION
(a) Do not stop the engine immediately after pulling a trailer,
or after driving at a high speed, or uphill drive. Let the en-
gine Idle for 20 to 120 seconds before turn the ignition
switch OFF (According as the driving condition, the idling
time varies).
(b) Avoid quick acceleration or quickly accelerating the en-
gine RPM immediately after the starting a cold engine.
(c) If the turbocharger is found to be defective, it must be re-
placed. Also, inspect a source of the trouble including
conditions of the turbocharger that having been used. Re-
pair or replace the followings as necessary:
(1) Engine oil (Level and quality)
(2) Oil lines leading to the turbocharger
(d) Pay due attention when removing and reinstalling the
turbocharger assembly. Do not drop, or do not give shock,
or do not grasp easily±deformed assembly parts such as
the actuator or push rod in removal and reinstallation.
(e) Before removal, cover both the intake and exhaust ports
and the oil inlet to prevent dirt or foreign objects from be-
ing introduced.
(f) If replacing the turbocharger, check for deposits in the oil
pipe. If necessary, replace the oil pipe too.
(g) Thoroughly remove old gasket sticking to the lubrication
oil pipe flange and the turbocharger oil flange.
(h) If replacing the bolt(s) or nut(s), must use Toyota genuine
parts to prevent breakage or deformation.
(i) If replacing the turbocharger, put 20 cm
3 (1.2 cu in.) of
fresh oil into the turbocharger oil inlet hole and turn the tur-
bine wheel by hand to spread oil to the bearing.
(j) If overhauling or replacing the engine, cut the fuel supply
after reassembly and crank the engine for 30 seconds to
feed oil throughout the engine then run the engine at idle
for 60 seconds.

A77122
13±4
± INTAKETURBO CHARGER SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(k) Since the turbine wheels runs at an extremely high speed,
if the engine is running without the air cleaner, case cover
and hose, damage to the turbine wheel will result by
introduced foreign particle.

1306S±02
A79032
Filter
AB
A59586
13±2
± INTAKEINTAKE AIR CONTROL SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT INTAKE AIR CONTROL VALVE ASSY
(a) With 34.7 kPa (260 mm Hg, 10.2 in. Hg) of vacuum ap-
plied to the actuator, check that the actuator rod moves.
(b) One minute after applying the vacuum, check that the ac-
tuator rod does not return.
(c) If the operation is not as specified, replace the intake air
control valve assembly.
NOTICE:
Do not touch the adjust screw.
2. INSPECT VACUUM SWITCHING VALVE ASSY NO.1
(a) Using an ohmmeter, measure resistance between each
terminal.
Resistance: 33 to 39
at 20
C (68
F)
(b) Check that air flows form port B to the filter.
(c) Apply battery voltage across the terminals.
(d) Check that air flows from port B to port A.

1302G±03
A77131
Vacuum Gage
35.7

3700 100
Throttle Valve Open Position


Engine Speed [r/min.]ON
OFF
A59594
SCV VSV
± INTAKEINTAKE AIR CONTROL SYSTEM (1AZ±FSE)
13±1
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE AIR CONTROL SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
1. INSPECT INTAKE AIR CONTROL SYSTEM
(a) Using a 3±way connector, connect vacuum gauge to the
actuator hose.
(b) Connect the hand±held tester to the DLC 3.
(c) Start the engine.
(d) Select the active test mode according to the message on
the hand±held tester.
Vacuum:
VSV ONApprox. 27 kPa (200 mm Hg, 7.9 in. Hg)
VSV OFF0 kPa (0 mm Hg, 0 in. Hg.)
(e) Shift the transmission into the P range and control the ac-
celerator pedal.
(f) Check the VSV operation using the hang±held tester.
HINT:
The value in the illustration is only for reference; the throttle
valve may operate diversely depend on the engine running
condition.

1209J±02
A77127
Ohmmeter
Resistance
A77128No ContinuityOhmmeter
A77129
Vacuum
A77130
6V Vacuum 12±18
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT VACUUM REGULATING VALVE ASSY
(a) Inspect E±VRV for open circuit
(1) Using an ohmmeter, measure resistance between
the terminals.
Resistance:
10 to 14
at 20
C (68
F)
(b) Inspect E±VRV for ground
(1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
Specified condition : No continuity
(c) Inspect E±VRV for air tightness
(1) Apply vacuum to the vacuum output port. Check
that the needle of vacuum pump indicates an in-
crease of 66.7 kPa (500 mmHg, 19.7 in.Hg) or
more.
If the air tightness is not as specified, replace the E±VRV.
(d) Inspect E±VRV operation
(1) Apply about 4 dry batteries of 1.5V in series.
(2) Check that the need does not move when vacuum
is applied to the vacuum outlet port.
If operation is not as specified, replace the E±VRV.

A82348
+B2
+B1EGR2
EGR1EGR4 EGR3
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
12±19
AVENSIS REPAIR MANUAL (RM1018E)
2. INSPECT EGR VALVE ASSY
(a) Using an ohmmeter, measure the resistance between the
terminals.
TerminalResistance at 20
C (68
F)
+B1 ± EGR119.6  1.4

+B1 ± EGR219.6  1.4

+B2 ± EGR319.6  1.4

+B2 ± EGR419.6  1.4