TOYOTA AVENSIS 2005 Service Repair Manual

05CDS−02
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
05 −3
AVENSIS Supplement (RM 1045E)
HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
The hand −held tester can be used at step 3, 4, 5, 7 and 10.
1 VEHICLE BROUGHT TO WORKSHOP
2 CUSTOMER PROBLEM ANALYSIS (See page 05 −6)
3 CONNECT THE HAND −HELD TESTER TO DLC3
HINT:
If the display indicates a communication fault in the tool, inspect the DLC3.
4 CHECK DTC AND FREEZE FRAME DATA (See page 05 −1 9)
HINT:
Record or print DTC and freeze frame data, if needed.
5 CLEAR DTC AND FREEZE FRAME DATA (See page 05 −1 9)
6 VISUAL INSPECTION
7 SETTING THE CHECK (TEST) MODE DIAGNOSIS (See page 05 −20)
8 PROBLEM SYMPTOM CONFIRMATION
HINT:
If the engine does not start, perform steps 10 and 12 first.
AMalfunction does not occur
BMalfunction occurs
B GO TO STEP 10
A

05−4
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
9 SYMPTOM SIMULATION
1 0 DTC CHECK (See page 05 −1 9)
AMalfunction code
BNo code
B GO TO STEP 12
A
11 DTC CHART (See page 05 −31)
GO TO STEP 14
12 BASIC INSPECTION (See page 05 −8)
AWrong parts not confirmed
BWrong parts confirmed
B GO TO STEP 17
A
1 3 PROBLEM SYMPTOMS TABLE (See page 05 −1 0)
AWrong circuit confirmed
BWrong parts confirmed
B GO TO STEP 17
A
1 4 CHECK ECM POWER SOURCE CIRCUIT (See page 05 −236)
1 5 CIRCUIT INSPECTION
AMalfunction not confirmed
BMalfunction confirmed
B GO TO STEP 18
A

−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
05 −5
AVENSIS Supplement (RM 1045E)
16 CHECK FOR INTERMITTENT PROBLEMS (See page 05 −7)
GO TO STEP 18
17 PARTS INSPECTION
1 8 IDENTIFICATION OF PROBLEM
1 9 ADJUSTMENT AND/OR REPAIR
20 CONFIRMATION TEST
END

05CDV−02
A83877
Ignition Coil Assy
Camshaft Position Sensor
VSV for EVAP
Combination Meter
DLC3
VSV for Intake Air Control Valve
Fuel Pump
ECM
Knock Sensor Camshaft Timing Oil Control Valve
(OCV)
Injector
Crankshaft Position
Sensor
Park/Neutral Position Switch
(Only for A/T Models)Engine Coolant
Temperature Sensor
Mass Air Flow Meter
Throttle Body Assy
Accelerator Pedal Assy
Heated Oxygen Sensor
(Bank 2 Sensor 2) *
2
Circuit Opening Relay
Heated Oxygen Sensor
(Bank1Sensor 2 ) *
1
Heated Oxygen Sensor
(Bank 2 Sensor1)*
2
Heated Oxygen Sensor
(Bank1Sensor1)*
1
Manifold Absolute Pressure Sensor
Fuel Pump (For High Pressure)
Injector Driver (EDU)
Brake Booster
Pressure Sensor
Fuel Pressure Sensor
(For Low Pressure)
FEFI Fuse
FIG2 Fuse
FAM2 Fuse
FTHROTTLE Fuse
FEFI Relay
FIG2 Relay
FINJ Relay
FEFI No.1Fuse
FEFI No.2 Fuse
FACT Fuse
FST Fuse
FIGN Fuse
FSTOP Fuse
FST Relay
Fuel Pump RelayFuel Pump Resister
*1: Bank1refers to the No.1and No.4 cylinders
*2: Bank 2 refers to the No.2 and No.3 cylinders
Engine Room R/B No.4:
Engine Room J/B No.4:Fuse Block:
Engine Room R/B No.1:
Engine Room J/B No.1:
Driver Side R/B:
Driver Side J/B: 05−2
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM1045E)
LOCATION

0313C−07
− SERVICE SPECIFICATIONSTIRE & WHEEL
03−29
AVENSIS Supplement (RM1045E)
TIRE & WHEEL
SERVICE DATA
Engine type:
2AZ−FSE
Tire sizeFront
kPa (kgf/cm2, psi)
Rear
kPa (kgf/cm2, psi)
Cold tire inflation pressure
205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
215/45R17 87W:
with 4 or less occupants
with 5 or more occupants220 (2.2, 32)*1
250 (2.5, 36)*2
220 (2.2, 32)*1
270 (2.7, 39)*2
240 (2.4, 35)*1
290 (2.9, 42)*2
240 (2.4, 35)*1
310 (3.1, 45)*2
220 (2.2, 32)*1
250 (2.5, 36)*2
220 (2.2, 32)*1
280 (2.8, 41)*2
240 (2.4, 35)*1
290 (2.9, 42)*2
240 (2.4, 35)*1
330 (3.3, 48)*2
Tire runout1.4 mm (0.055 in.) or less
Imbalance after adjustment8.0 g (0.018 lb) or less
*1: For driving under160 km/h (100 mph)
*2: For driving at160 km/h (100 mph) or over

031E5−02
− SERVICE SPECIFICATIONSIGNITION
03−25
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Ignition coil assy x Cylinder head cover sub−assy9.09280 in.
lbf
Spark plug x Cylinder head sub−assy1919414
Camshaft position sensor x Cylinder head sub−assy9.09279 in.
lbf
Wire harness protector x throttle body bracket8.48674 in.
lbf
Engine wire No. 3 (battery negative terminal) x Battery5.45548 in.
lbf
Crankshaft position sensor x Timing chain cover sub−assy9.09279 in.
lbf

054JE−09
A85347
Mass Air Flow Meter
DLC3
Accelerator Pedal Assy
(Accelerator Pedal
Position Sensor)
EDUECM
Engine Room R/B No. 1:
FEDU Relay
FEDU Fuse
Glow Plug Relay
Camshaft Position SensorInjector
Crankshaft Position Sensor
Engine Coolant Temperature Sensor Fuel Pressure Sensor
Fuse Block
FST Fuse
Driver Side J/B
FGAUGE Fuse
FSTOP Fuse
Driver Side R/B
FST Relay
E−VRV Pressure Discharge Valve Glow Plug
Exhaust Gas Temperature
Sensor (on down stream)Intake Air Temperature Sensor
EGR Valve
Turbo Pressure Sensor
Intake Shutter (Throttle Valve)
Suction Control Valve
Fuel Temperature Sensor
Supply Pump Exhaust Gas Temperature
Sensor (on up stream)
Exhaust Fuel Addition Injector
A/F Sensor
Engine Room R/B No. 3:
FGLOW Fuse
EGR Valve
Position Sensor
Intake Shutter
(Throttle Valve)
Position Sensor
Differential Pressure Sensor 05−254
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
LOCATION

05DVP−02
A8570 1
Sample:
Injector
Compensation Code
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −253
AVENSIS Supplement (RM 1045E)
ECD SYSTEM ( 1CD −FTV)(From September, 2003)
PRECAUTION
1. INJECTOR COMPENSATION CODE
(a) Since each injector has its own fuel injection characteris- tic, the ECM compensates this by slightly modifying injec-
tion duration in order to optimize fuel injection volume.
Compensating data for the optimum injection volume, in
the form of a 30 −digit −alphanumeric value, has been im-
printed on the head portion of each injector as the injector
compensation code.
(b) The injector compensation code will be required to regis- ter to the ECM when replacing the injectors or the ECM
(see page 05 −277).
(c) If an incorrect injector compensation code was registered
to the ECM, it may rattle the engine assembly or the en-
gine idling may become rough. In addition, it may become
a cause of engine failure or shorten the life of the engine.
2. DIFFICULT TO ENGINE START, ENGINE STALL OR BLACK SMOKE
(a) If the customer ’s problem description is applicable to one of the following problems, refer to the troubleshooting on
the pages shown below:
(1 ) Engine start difficulties, or engine stall, see page
05−502.
(2) Black smoke, see page 05 −512.

A76882
Battery FL MAINIGN
B−G11
E9
2 6
Engine
Room
J/B No.4Engine Room
R/B No.1
AM2
1 2
B−G4
18Driver
Side J/B
B−W B−R
WECM
DH
DA B−R
B−R 1
1A 1
1
4A
1 4B(LHD) (RHD)IP1 IE41
1
I13
Ignition Switch
AM2
IG2
(LHD)J8C
(RHD)J26A
(LHD)J8C
(RHD)J26AB−WCheck
Engine
Warning
LightW
C11
Combination Meter
229
J/C Engine Room
J/B No.1
− DIAGNOSTICSSFI SYSTEM (2AZ−FSE)
05−251
AVENSIS Supplement (RM1045E)
CHECK ENGINE WARNING LIGHT CIRCUIT
CIRCUIT DESCRIPTION
The CHK ENG is used to indicate the ECM’s detection of a vehicle malfunction.
The instrument panel IGN fuse provides the circuit power and the ECM provides the circuit ground that illumi-
nates the CHK ENG.
CHK ENG operations should be checked visually:
The CHK ENG should be illuminated when the ignition is first turned to ON. If the CHK ENG is always ON
or OFF, use the hand−held tester and follow the procedures below to determine the cause of the problem.
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
Troubleshoot each trouble symptom in accordance with the chart below.
CHK ENG remains onStart inspection from step1
CHK ENG is not illuminatedStart inspection from step 3
05CJB−02

A67445ECM ConnectorW
E9
05
−252
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
1 CLEAR DTC
(a) Connect the hand −held tester to the DLC 3.
(b) Turn the ignition switch to ON and turn the hand −held tester ON.
(c) Read the DTC (see page 05 −1 9) .
(d) Clear the DTC (see page 05 −1 9) .
(e) Check that the CHK ENG is not illuminated. Standard: CHK ENG is not illuminated
OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC(See page 05 −7)
NG
2 CHECK HARNESS AND CONNECTOR(CHECK FOR SHORT IN WIRE HARNESS)
(a) Disconnect the E9 ECM connector.
(b) Turn the ignition switch to ON.
(c) Check that the CHK ENG is not illuminated. Standard: CHK ENG is not illuminated
(d) Reconnect the ECM connector.
NG CHECK AND REPAIR HARNESS AND CONNECTOR
OK
REPLACE ECM (See page 10− 65 of Pub. No. RM 1018E AVENSIS)
3 CHECK CHK ENG CONDITION
(a) Check that the CHK ENG is illuminated when turning the ignition switch to ON.
Standard: CHK ENG is illuminated
OK SYSTEM OK
NG
4 INSPECT COMBINATION METER ASSY(CHK ENG CIRCUIT)
(a) See the combination meter troubleshooting procedure on page 05 −1 0.
NG REPAIR OR REPLACE BULB OR COMBINATION METER ASSEMBLY
OK
CHECK AND REPAIR HARNESS AND CONNECTOR (COMBINATION METER −ECM)