TOYOTA AVENSIS 2005 Service Repair Manual

B09793
Convex
Concave
B08249
Upward
B08253
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±19
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(e) Meet the injector positioning convex to the positioning
concave at the cylinder head side and install the injector
to the cylinder head.
NOTICE:

At this time, insert the injector until it touches the
nozzle sheet surface.

When installing the injector to the cylinder head and
in case that the injector comes to float up with the
reaction of O±ring, pull out the injector once, install
it again.

During the time after equipping the head cover and
before installing the injection pipe, install the irregu-
lar object prevention cover.

Do not exchange the injector cylinder.
(f) Place the 4 nozzle holder clamps to each injector.
49. INSTALL NOZZLE HOLDER CLAMP
(a) Set the washer on the nozzle holder clamp as shown in
the illustration.
(b) Tighten the bolts.
HINT:
Apply a light coat of engine oil on the threads and under the
heads of the nozzle holder clamp bolts.
Torque: 27 N
m (275 kgf
cm, 20 ft
lbf)
NOTICE:
At this time, the clamp has its cam cap bolt as a fulcrum and
clip the injector at the fork portion.

90

180

B08307
B08311
B08312
Plug
GasketOverflow Screw
Ball Spring 14±20
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
50. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Place the leakage pipe and 5 new gaskets.
NOTICE:
Do the installation of the gasket craw within the angle
range shown in the illustration.
(b) Apply a light coat of oil onto 4 hollow screws and union
bolt.
(c) Tighten the 4 hollow screws and union bolt by hand.
(d) Tighten the 4 hollow screws and union bolt.
Torque:
Hollow screw 18 N
m (184 kgf
cm, 13 ft
lbf)
Union bolt 22 N
m (224 kgf
cm, 16 ft
lbf)
(e) Check that there is no leak from nozzle leakage pipe con-
nection.
(1) Disconnect the fuel hose, and remove the check
valve, No. 2 nozzle leakage pipe and gasket.
(2) Purchase a new check valve.
HINT:
Part No. 23122±27010
(3) Remove the plug, gasket, spring and ball.
(4) Install the plug with the gasket to the overflow
screw.
Torque: 9.8 N
m (100 kgf
cm, 7 ft.
lbf)
(5) Install the No. 2 nozzle leakage pipe and gasket
with the check valve to the cylinder head.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(6) Apply a light coat of soapy water (any fluid to detect
fuel leakage) on the nozzle leakage pipe connec-
tion.

A56050
New Gasket
Union Bolt
Hollow
Screw
SST
No. 2 Nozzle
Leakage Pipe
Check
Valve
New Gasket
B08328
Check
ValveNo. 2 Nozzle
Leakage Pipe
New Gasket
A09663
: Seal Packing
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±21
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
(7) Using SST (turbocharger pressure gauge), apply
the SST to the fuel return side of the No. 2 nozzle
leakage pipe, and maintain 100 kPa (1 kgf/cm
2,
14.5 psi) of pressure for 600 seconds to check that
there are no bubbles from the soap±applied places.
SST 09992±00242
(8) After checking fuel leaks, wipe off soapy water from
nozzle leakage pipe connection.
(9) Remove SST, check valve, No. 2 nozzle leakage
pipe and gasket.
(10) Reinstall the No. 2 nozzle leakage pipe and a new
gasket with the check valve.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
HINT:
Never reinstall the disassembled check valve on the engine.
(11) Reconnect the fuel hose to the No. 2 nozzle leak-
age pipe.
51. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head.
Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with 10 bolts.
Torque: 13 N
m (135 kgf
cm, 10 ft
lbf)
(e) Install 4 new nozzle holder seals.

190AI±01
A62720
Drive End Frame Assy Generator w/ Clutch Pulley
Alternator Pulley CapGenerator Rotor Assy
Rear End Cover
Sub±Assy Rear Seal Plate
Generator Brush
Holder Assy
Front Seal
Plate
Alternator Coil Assy
N´m (kgf´cm, ft´lbf)
: Specified torque
5.8 (59, 51 in.´lbf)
1.8 (18, 16 in.´lbf)
4.6 (47, 41 in.´lbf)
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
19±31
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
GENERATOR ASSY(130A) (1CD±FTV)
COMPONENTS

05C66±01
FI0534
A76859
Hand±Held Tester
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
05±5
AVENSIS REPAIR MANUAL (RM1018E)
PRE±CHECK
1.DIAGNOSIS SYSTEM
(a)Description for Euro±OBD (European spec.)

When troubleshooting Euro±OBD vehicles, the
only difference from the usual troubleshooting pro-
cedure is that you connect the vehicle to the OBD
scan tool complying with ISO 15031±4 or hand±
held tester, and read the various data output from
the vehicle's ECM.

Euro±OBD regulations require that the vehicle's
on±board computer illuminates the check engine
warning light (CHK ENG) on the instrument panel
when the computer detects a malfunction in the
emission control system / components or in the
powertrain control components which affect ve-
hicle emissions, or a malfunction in the computer. In
addition to an illumination of the CHK ENG when a
malfunction is detected, the applicable Diagnostic
Trouble Codes (DTC) prescribed by ISO 15031±4
are recorded in the engine ECU memory (See page
05±16). If the malfunction does not reoccur in 3 con-
secutive trips, the CHK ENG goes off automatically
but the DTCs remain recorded in the ECM memory.

To check the DTCs, connect the OBD scan tool or
hand±held tester to Data Link Connector 3 (DLC3)
on the vehicle. The OBD scan tool or hand±held
tester also enables you to erase the DTCs and
check freezed frame data and various forms of en-
gine data. (For operating instructions, see the OBD
scan tool's instruction book.)
DTCs include ISO controlled codes and manufac-
turer controlled codes. ISO controlled codes must
be set as prescribed by the ISO, while manufacturer
controlled codes can be set freely by the manufac-
turer within the prescribed limits (See DTC chart on
page 05±16).

The diagnosis system operates in the normal mode
during normal vehicle use. It also has a check (test)
mode for technicians to simulate malfunction symp-
toms and troubleshoot. Most DTCs use 2 trip detec-
tion logic* to prevent erroneous detection, and to
ensure a thorough malfunction detection. By
switching the ECM to the check (test) mode using
hand±held tester when troubleshooting, a techni-
cian can cause the CHK ENG to illuminate for a mal-
function that is only detected once or momentarily
(Hand±held tester only) (See step 3).

* 2 trip detection logic
When a logic malfunction is first detected, the pend-

FI0534
05±6
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
ing fault code is stored in the ECM memory (1st trip).
If the same malfunction is detected again during the
second drive test, this second detection causes the
CHK ENG to illuminate (2nd trip) (However, the igni-
tion switch must be turned OFF between the 1st trip
and 2nd trip).

Freeze frame data:
Freeze frame data records the engine condition
when a misfire (DTCs P0300 ± P0304) or fuel trim
malfunction (DTCs P0171) or other malfunction
(first malfunction only), is detected.
Because freeze frame data records the engine
conditions (fuel system, calculated load, engine
coolant temperature, fuel trim, engine speed, ve-
hicle speed, etc.) when the malfunction is detected,
when troubleshooting it is useful for determining
whether the vehicle was running or stopped, the en-
gine warmed up or not, the air±fuel ratio lean or rich,
etc. at the time of the malfunction.

Priorities for troubleshooting:
If troubleshooting priorities for multiple DTCs are
given in the applicable DTC chart, these should be
followed.
If no instructions are given, troubleshoot according to the fol-
lowing priorities.
(1) DTCs other than fuel trim malfunction (DTCs
P0171) and misfire (DTCs P0300 ± P0304).
(2) Fuel trim malfunction (DTCs P0171).
(3) Misfire (DTCs P0300 ± P0304).
(b) Description for M±OBD (Except European spec.)

When troubleshoot Multiplex OBD (M±OBD) ve-
hicles, the only difference from the usual trouble-
shooting procedure is that you connect the hand±
held tester to the vehicle, and read the various data
output from the vehicle's ECM.

A76859
Hand±Held Tester
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
05±7
AVENSIS REPAIR MANUAL (RM1018E)

The vehicle's on±board computer illuminates the
check engine warning light (CHK ENG) on the
instrument panel when the computer detects a mal-
function in the computer itself or in drive system
components. In addition to an illumination of the
CHK ENG when a malfunction is detected, the ap-
plicable Diagnostic Trouble Codes (DTCs) are re-
corded in the ECM memory (See page 05±16).
When the malfunction does not reoccur, the CHK
ENG is indicated until the ignition switch is turned
off, and then the CHK ENG is not indicated when
the ignition switch is turned on but the DTCs remain
recorded in the ECM memory.

To check the DTCs, connect the hand±held tester
to the Data Link Connector 3 (DLC3) on the vehicle
or read the DTC which is indicated on the multi in-
formation display when TC and CG terminals on the
DLC3 are connected. The hand±held tester also
enables you to erase the DTCs and check the
freeze frame data and various forms of engine data.
(for operating instructions, see the instruction
book.)

The diagnosis system operates in the normal mode
during normal vehicle use. It also has a check (test)
mode for technicians to simulate malfunction symp-
toms and troubleshoot. Most DTCs use 2 trip detec-
tion logic* to prevent erroneous detection, and to
ensure a thorough malfunction detection. By
switching the ECM to the check (test) mode using
hand±held tester when troubleshooting, a techni-
cian can cause the CHK ENG to illuminate for a mal-
function that is only detected once or momentarily
(Hand±held tester only) (See step 3).

* 2 trip detection logic
When a logic malfunction is first detected, the pend-
ing fault code is stored in the ECM memory (1st trip).
If the same malfunction is detected again during the
second drive test, this second detection causes the
CHK ENG to illuminate (2nd trip) (However, the igni-
tion switch must be turned OFF between the 1st trip
and 2nd trip).

3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
FI0534
05±8
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

Freeze frame data:
Freeze frame data records the engine conditions
(fuel system, calculator load, water temperature,
fuel trim, engine speed, vehicle speed, etc.) when
a malfunction is detected. When troubleshooting,
it is useful for determining whether the vehicle was
running or stopped, the engine was warmed up or
not, the air±fuel ratio was lean or rich, etc. at the
time of the malfunction.
(c) Check the DLC3.
The vehicle's ECM uses the ISO 9141±2 (Euro±OBD)/
ISO 14230(M±OBD) communication protocol. The termi-
nal arrangement of DLC3 complies with ISO 15031±03
and matches the ISO 9141±2/ ISO 14230 format.
Terminal No.Connection / Voltage or ResidenceCondition
7Bus + Line / Pulse generation+During transmission
4Chassis Ground ± Body Ground / 1
or lessAlways
16Battery Positive ± Body Ground / 9 to 14 VAlways
HINT:
If the display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the hand±held tester to
the DLC3, turned the ignition switch ON and operated the
hand±held tester, there is a problem on the vehicle side or tool
side.

If communication is normal when the tool is connected to
another vehicle, inspect the DLC3 on the original vehicle.

If communication is still not possible is when the tool is
connected to another vehicle, the problem is probably in
the tool itself, so consult the Service Deparment listed in
the tool's instruction manual.
(d) Inspect the battery voltage.
Battery voltage: 11 to 14 V
If voltage is below 11V, recharge the battery before proceeding.
(e) Check the CHK ENG.
(1) The CHK ENG lamp comes on when the ignition
switch is turned ON and the engine is not running.
HINT:
If the CHK ENG lamp is not illuminated, troubleshoot the com-
bination meter.
(2) When the engine is started, the CHK ENG should
go off. If the lamp remains on, it means that the diag-
nosis system has detected a malfunction or ab-
normality in the system.

A76859
Hand±Held Tester
±
DIAGNOSTICS SFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±9
AVENSIS REPAIR MANUAL (RM1018E)
2. DTC CHECK (Nomal Mode) :
NOTICE:
Hand±held tester only:
When the diagnosis system is switched from the normal
mode to the check (test) mode, it erases all DTCs and freeze
frame data recorded in the normal mode. So before switch-
ing modes, always check the DTCs and freeze frame data,
and then write them down.
(a) Checking DTCs using the hand±held tester.
(1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON and switch the hand±
held tester main switch ON.
(3) Use the hand±held tester to check the DTCs and freeze frame data and then write them down. The
hand±held tester's instruction book.
(4)See page 05±16 to confirm the details of the DTCs.
(b) Clearing the DTCs using the hand±held tester: (1) Connect the hand±held tester to the DLC3.
(2) Turn the ignition switch ON.
(3) When operating hand±held tester to erase the
codes, the DTCs and freeze frame data will be
erased. (See the hand±held tester's instruction
book for operating instructions.)
(c) Clearing the DTCs not using the hand±held tester: (1) Disconnect the battery terminal or remove the EFIfuse for more than 60 seconds.
3. DTC CHECK (Check Mode):
HINT:
Hand±held tester only:
Compared to the normal mode, the check mode has more sens-
ing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check (test) mode.
(a) Proceduce for check mode using hand±held tester.
(1) Check the initial conditions

Battery positive voltage 11V or more.

Throttle valve fully closed.

Transmission in the ºPº or ºNº position.

Air conditioning switched OFF.
(2) Turn the ignition switch OFF.

A76859
Hand±Held Tester
FI3605
ON
OFFBlinking
0.13 Second
05±10
± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Connect the hand±held tester to the DLC3.
(4) Turn the ignition switch and the hand±held tester
main switch ON.
(5) Switch the hand±held tester from the normal mode
to the check (test) mode. The CHK ENG blinks in
0.13 sec interval as shown in the illustration.
NOTICE:
If the hand±held tester switches the ECM from the normal
mode to the check mode or vice±versa, or if the ignition
switch is turned from ON to ACC or OFF during the check
mode, the DTC and freeze frame data will be erased.
(6) Start the engine. (The CHK ENG lamp goes out af-
ter the engine start.)
(7) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTC, etc.
(8) After simulating the malfunction conditions, use the
hand±held tester diagnosis selector to check the
DTCs and freeze frame data, etc.
HINT:
Be sure not to turn the ignition switch OFF, because the diagno-
sis system is changed from the check mode to the nomal mode
and will result in all of the DTCs and freeze frame data being
erased.
(9) After checking the DTCs, inspect the applicable cir-
cuit.
(b) Clearing the DTCs using the hand±held tester
(1) Connect the hand±held tester to DLC3.
(2) Turn the ignition switch ON.
(3) When operating hand±held tester to erase the
codes, the DTCs and freeze frame data will be
erased. (See the hand±held tester's instruction
book for operating instructions.)
(c) Clearing the DTCs not using the hand±held tester:
(1) Disconnect the battery terminal or remove the EFI
fuse for more than 60 seconds.