compression ratio TOYOTA AVENSIS 2005 Service Workshop Manual

A81504
Injector Cross Section DiagramPiston
Solenoid Valve
Nozzle Needle
05±658
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP1238INJECTOR MALFUNCTION
HINT:

For more information on the injector and the common rail system, see page 05±517.

If P1238 is present, use the diagnostic trouble code matrix for fuel sys\
tem, see page 05±517.
CIRCUIT DESCRIPTION
The ECM detects combustion deterioration for specific cylinder.
HINT:

The cylinder that has compensation learned value for INJ VOL varies from other cylinders may be mal-
functioning.

If DTC P0093 (Fuel leaks in high±pressure area) is present simultan\
eously, leakage malfunction of the
cylinder probably be occurred.

If DTC P0200 (Open or short in EDU or injector circuit) is present sim\
ultaneously, there probably be
faulty circuit located between the ECM and the injector including the ED\
U.

If only DTC P1238 (Injector malfunction) is present, probably the injector is \
mechanical malfunction
or insufficient compression (valve clearance, etc) has occurred, not an open o\
r short malfunction of
the ECM, EDU and injector circuit.

Solenoid valve of the injector is the same type of the pressure discharg\
e valve.
05CQ0±01

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±659
AVENSIS REPAIR MANUAL (RM1018E)DTC No.
DTC Detection ConditionMain Trouble AreaRelated Trouble Area
P1238Engine speed variation is large when idling.


Injector

EDU (P0200is set simultaneous-
ly)

Open or short in engine wire
(P0200is set simultaneously)

Connector connection (P0200is
set simultaneously)

Compression pressure

Valve clearance

Valve timing

ECM
HINT:
After confirming DTC P1238, use the hand±held tester to confirm the fuel pressure inside the common rail
in the ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / COMN RAIL PRESSº.
Engine SpeedFuel Pressure (MPa)
IdlingApprox. 30 to 40
Running the engine at 2,500 rpm (No engine load)Approx. 50 to 100
MONITOR DESCRIPTION
P1238 (Injection malfunction, exclude open or short in injector circuit):
This DTC will be set if the engine speed variations between each cylinder is\
large. The ECM monitors
changes in the crankshaft rotation speed using the crankshaft position sensor f\
or detecting poor combus-
tion. Also, it identifies faulty cylinder using the camshaft position sensor. The fluctuation counter increments
when irregular crankshaft rotation speed variation exceeds the threshold at i\
dling. Therefore, either one of
the cylindershas very poor combustion (Rough idle), the ECM sets this DTC.
MONITOR STRATEGY
Required sensorsCrankshaft position sensor
Frequency of operationContinuous
Duration10 min.
CHK ENG operation2 driving cycles
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
EngineAt idling
Engine speed500 rpm±
Engine coolant temperature20 C (68 F)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
The number of irregular changes in the crankshaft rotation speed
HINT:
The number of irregular changes in the crankshaft rotation speed indicat\
es the insufficient combustion cylin-
der.
WIRING DIAGRAM
Refer to DTC P0200 on page 05±604.

05CDX−02
05 −1 0
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
PROBLEM SYMPTOMS TABLE
When the malfunction is not confirmed in the diagnostic trouble code check and the problem still can not be
confirmed in the basic inspection, proceed to this matrix chart and troubleshoot according to the numbered
order given below.
SymptomSuspected AreaSee page
Engine does not crank (Does not start)
1. Starter
2. Starter relay
3. Park/neutral position switch19 −1
1 9 −1
* 1
No initial combustion (Does not start)
1 . ECM power source circuit
2. Ignition coil assy
3. Fuel pump control circuit
4. Injector circuit05 −236
05 −1 67
05 −24 1
05 −1 36
No complete combustion (Does not start)
1. Ignition coil assy
2. Fuel pump control circuit
3. Injector circuit05 −1 67
05 −24 1
05 −1 36
Difficult to start (Engine cranks normally)
1. Starter signal circuit
2. Ignition coil assy
3. Spark plug
4. Compression
5. Injector circuit
6. Fuel pump control circuit05 −249
05 −1 67
1 8 − 3
1 4 −1
05 −1 36
05 −24 1
Difficult to start with cold engine
1. Starter signal circuit
2. Injector circuit
3. Ignition coil assy
4. Spark plug
5. Fuel pump control circuit05 −249
05 −1 36
05 −1 67
1 8 − 3
05 −24 1
Difficult to start with hot engine
1. Starter signal circuit
2. Injector circuit
3. Ignition coil assy
4. Spark plug
5. Fuel pump control circuit05 −249
05 −1 36
05 −1 67
1 8 − 3
05 −24 1
High engine idle speed (Poor idling)
1. ECM power source circuit
2. Park/neutral position switch
3. Back up power source circuit05 −236
* 1
05 −1 99
Low engine idle speed (Poor idling)
1. Park/neutral position switch
2. Injector circuit
3. Back up power source circuit
4. Fuel pump control circuit* 1
05 −1 36
05 −1 99
05 −24 1
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 −55
05 −61
05 −1 36
05 −24 1
05 −1 67
1 4 −1
05 −1 99
Hunting (Poor idling)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. ECM power source circuit05 −55
05 −61
05 −236
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 −55
05 −61
05 −1 36
05 −1 67
05 −24 1
Muffler explosion after fire (Poor driveability)
1. Ignition coil assy
2. Spark plug
3. Injector circuit05 −1 67
1 8 − 3
05 −1 36

05−446
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E) DTC No.
DTC Detection ConditionMain Trouble AreaRelated Trouble Area
SExcess or low fuel addition volume from exhaust
fuel addition injector:
When air−fuel ratio deviates from a value estimated
by ECM while the injector adds fuel
(1trip detection logic)SOpen in exhaust temperature
sensor circuit
SA/F sensor
SExhaust gas temperature sensor
SSupply pump assy
SMass air flow meter
SFuelleaksinexhaustfueladdi-
P1386
SLow fuel addition volume from exhaust fuel addition
injector:
When learning value (*3) exceeds standard level
(1trip detection logic)SOpen or short in exhaust fuel
addition injector circuit
SExhaust fuel addition injector
SDPNR catalytic converter (Man-
ifold converter sub−assy)
SFuelleaksinexhaustfueladdi-
tion injector
SMain injector
SCylinder compression pressure
SValve clearance
SValve timing
Airintakesystemhasblockages
SExhaust fuel addition injector nozzle stuck open:
When air−fuel ratio becomes RICHER than standard
level, or exhaust gas temperature reaches higher
than standard level
(1trip detection logic)
SAir intake system has blockages
SAir intake system has leakage
SExhaust system has blockages
SExhaust system has leakage
SEGR system has blockages
SEGR system has leakage
SECM
*3: Correction learning value of the fuel addition volume to raise the DPNR catalyst temperature to a target
range.
HINT:
DTC P2047 (Reductant injector circuit/open [bank1unit1]) will be present if there is an open malfunction in
the exhaust fuel addition injector circuit.

A81504
Injector Cross Section Diagram:Piston
Solenoid Valve
Nozzle Needle
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
05 −43 1
AVENSIS Supplement (RM1045E)
DTC P 1238 INJECTOR MALFUNCTION
HINT:
S For more information on the injector and the common rail system, see page 05 −255.
S If P1238 is present, refer to the diagnostic trouble codes (DTCs) table for the fuel system on page
05 −255.
CIRCUIT DESCRIPTION
The ECM detects combustion deterioration for a specific cylin-
der.
HINT:
SThe cylinder, which has compensation value for INJ VOL
that varies from other cylinders, may be malfunctioning.
SIf DTC P0093 (Fuel leaks in high −pressure area) is pres-
ent simultaneously, leakage malfunction of the cylinder
probably be occurred.
SIf DTC P0200 (Open or short in EDU or injector circuit) is
present simultaneously, there probably be faulty circuit lo-
cated between the ECM and the injector including the
EDU.
SIf only DTC P1238 (Injector malfunction) is present, prob-
ably injector mechanical malfunction or insufficient com-
pression (valve clearance etc) has occurred, not an open
or short malfunction of the ECM, EDU and injector circuit.
SSolenoid valve of the injector is the same type that of the
pressure discharge valve.
DTC No.DTC Detection ConditionMain Trouble AreaRelated Trouble Area
P1238Engine speed fluctuation is large when idling
(2 trip detection logic)
S Injector
S EDU (P0200 is set simultaneous-
ly)
S Open or short in engine wire har-
ness (P0200 is set simultaneous-
ly)
S Connector connection (P0200 is
set simultaneously)
S Compression pressure
S Valve clearance
SValve timing
S ECM
HINT:
After confirming DTC P1238, check the internal fuel pressure in ”DIAGNOSIS / OBD/MOBD / DATA LIST
/ ALL / COMN RAIL” using the hand −held tester.
Reference:
Engine SpeedFuel Pressure (MPa)
IdlingApproximately 30 to 40
2,500 rpm (No engine load)Approximately 50 to 100
05CQ0 −05

SST
A09620
A85427
TDC Mark
Dot Mark90_
A09624
A09625
14−154
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
45. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the camshaft oil seal retainer edge.
SST 09223−46011
(b) Apply multipurpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign object.
46. 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.
47. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following procedures
should be carried out.
(a) Place the camshaft carrier on the cylinder head.
(b) Install the camshaft.
(c) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(d) Place the intake camshaft on the camshaft carrier so that
the No. 3 and No. 4 of the cylinder cam lobes face down-
ward as shown in the illustration.

A87962
A09609
A09680
SST
A09611
A09606
− ENGINE MECHANICALTIMING BELT (1CD−FTV)(From September, 2003)
14−141
AVENSIS Supplement (RM1045E)
21. REMOVE TIMING CHAIN COVER PLATE
(a) Remove the bolt and timing chain cover plate.
22. REMOVE TIMING BELT
HINT:
If reusing the timing belt, draw an arrow on the belt which indi-
cates the engine revolution direction and put match marks on
the pulleys and belt before removing. This operation will be very
helpful when reinstalling the timing belt.
(a) Alternately loosen the 2 bolts to remove the timing belt
tensioner.
(b) Remove the timing belt.
23. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, set the pulleys of the camshaft and injection
pump so that each timing mark of the pulleys is aligned
with its timing mark on the cylinder head assembly and
water pump assembly.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Using the crankshaft pulley bolt, align the dot mark of the
crankshaft timing gear with the TDC mark of the oil pump
by turning the crankshaft.
NOTICE:
Be very careful in turning the camshaft and crankshaft.
Since the valve head and piston head are sensitive, contact
of the piston head with the valve heads may damage them.

A61186
SST
A84289
14−11 4−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
53. REMOVE FLYWHEEL SUB −ASSY
(a) Hold the crankshaft with SST. SST 09213 −54015 (09213 −70020), 09330 −00021
(b) Using a Torx socket wrench (T55), remove the 8 Torx
screws and flywheel.
54. REMOVE REAR END PLATE
(a) Remove the 2 bolts and rear end plate.
55. REMOVE DRIVE SHAFT BEARING BRACKET
56. REMOVE ENGINE MOUNTING BRACKET FR
57. REMOVE ENGINE MOUNTING BRACKET RR
58. REMOVE GLOW PLUG ASSY (See Pub. No. RM1018E on page 19 −33)
59. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
60. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
61. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
62. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
63. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
64. REMOVE TIMING BELT GUIDE
65. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
66. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
67. REMOVE TIMING BELT (See page 14 −138)
HINT:
If reusing the timing belt, draw an arrow on the belt which indicates the engine revolution direction and put
match marks on the pulleys and belt before removing. This operation will be very helpful when reinstalling
the timing belt.
68. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
69. REMOVE GENERATOR BRACKET NO.1
(a) Remove the 2 bolts and generator bracket.

141NB−01
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (2AZ −FSE)
14 −79
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −4)
2. REMOVE FRONT WHEEL RH
3. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14 −23)
4. REMOVE ENGINE ROOM COVER SIDE (See page 14 −23)
5. REMOVE ENGINE UNDER COVER LH (See page 14 −23)
6. REMOVE ENGINE UNDER COVER NO.4 RH (See page 14 −23)
7. REMOVE ENGINE UNDER COVER RH (See page 14 −23)
8. DRAIN COOLANT (See page 16 −7)
9. DRAIN ENGINE OIL (See page 17 −6)
10. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −45)
11. REMOVE FUEL PRESSURE PULSATION DAMPER ASSY
12. SEPARATE FUEL TUBE SUB −ASSY (See page 11 −4)
13. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
14. REMOVE FUEL PUMP ASSY (See page 11 −24)
15. REMOVE FAN AND GENERATOR V BELT (See page 14 −5)
SST 09249 −63010
16. REMOVE GENERATOR ASSY (See page 19 −8)
17. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −2)
18. SEPARATE VANE PUMP ASSY (See page 14 −45)
19. REMOVE IGNITION COIL ASSY (See page 14 −45)
20. SEPARATE RETURN TUBE SUB −ASSY (See page 14 −45)
21. SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) (See page 14 −45)
22. REMOVE VANE PUMP OIL RESERVOIR ASSY (See page 14 −45)
23. REMOVE OIL RESERVOIR BRACKET NO.1 (See page 14 −45)
24. SEPARATE ENGINE WIRE (See page 14 −23)
25. REMOVE COOLER BRACKET (LHD STEERING POSITION TYPE) (See page 14 −45)
26. REMOVE ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE)
(See page 14 −45)
27. REMOVE CYLINDER HEAD COVER SUB −ASSY (See page 14 −45)
28. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −45)
29. REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14 −45)
30. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (See page 14 −45)
31. REMOVE CRANKSHAFT PULLEY (See page 14 −45)
SST 09213 −54015 (91651 −60855), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05021)
32. REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14 −45)
33. REMOVE CRANKSHAFT POSITION SENSOR (See page 14 −45)
34. REMOVE OIL PAN SUB −ASSY (See page 14 −45)
SST 09032 −00100
35. REMOVE V −RIBBED BELT TENSIONER ASSY (See page 14 −45)
36. REMOVE TIMING CHAIN OR BELT COVER SUB −ASSY (See page 14 −45)
37. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14 −45)
38. REMOVE CHAIN TENSIONER SLIPPER (See page 14 −45)
39. REMOVE CHAIN VIBRATION DAMPER NO.1 (See page 14 −45)
40. REMOVE TIMING CHAIN GUIDE (See page 14 −45)
41. REMOVE CHAIN SUB −ASSY (See page 14 −45)

1509W−02
A85748
30 (302, 22)43 (440, 32)zGasketzGasket
Floor Panel Brace Front Exhaust Pipe Assy Front
Compression Spring
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part
43 (440, 32)
Compression Spring
Exhaust Pipe Assy Tail
Air−fuel Ratio Sensor
43 (440, 32)
44 (449, 33)
− EXHAUSTEXHAUST PIPE ASSY (1CD−FTV)(From September,
2003)15−5
AVENSIS Supplement (RM1045E)
EXHAUST PIPE ASSY (1CD−FTV)(From September, 2003)
COMPONENTS