fuel filter TOYOTA AVENSIS 2005 Service Workshop Manual

±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
05±379
AVENSIS REPAIR MANUAL (RM1018E)
8CHECK AIR INDUCTION SYSTEM
(a)Check for vacuum leaks in the air induction system.
NGREPAIR OR REPLACE AIR INDUCTION SYSTEM
OK
9CHECK FUEL PRESSURE(LOW PRESSURE) (See page 11±33)
NGCHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
10CHECK FUEL PRESSURE(HIGH PRESSURE) (See page 11±33)
NGCHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
11CONFIRM IF ANY MISFIRING DTCS WERE PRESENT AT STEP 1
(a)Misfiring DTC ºP0301, P0302, P0303 and/or P0304º was present at step 1. NOREPLACE HEATED OXYGEN SENSOR
YES
12REPLACE FUEL INJECTOR ASSY (See page 11±42)
HINT:
If one or more the misfiring DTCs ºP0301, P0302, P0303 and/or P0304º\
were present at step 1, replace the
injector(s) mounted on the misfiring cylinder(s) that is referred by the DTC(s)\
with normal injector(s). GO
13PERFORM CONFIRMATION DRIVING PATTERN (See page 05±363)
HINT:
Clear all DTCs prior to performing the confirmation driving pattern.GO

05±424
±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
8REPLACE FUEL INJECTOR OF MISFIRING CYLINDER
(a)Read the DTC and check which of the cylinders causes the misfiring DTC (See page 05±294).
(b)Remove the injector of the misfiring cylinder and other normal injector \
(See page 11±42).
(c)Swap the injector of misfiring cylinder for the normal injector. GO
9PERFORM CONFIRMATION DRIVING PATTERN
HINT:
Clear all DTCs prior to performing the confirmation driving pattern.GO
10READ OUTPUT DTC(MISFIRE DTCS ARE OUTPUT AGAIN)
(a)Read the DTC using the hand±held tester. Result:
Display (DTC output)Proceed to
The same DTC is output againA
The other DTC is outputB
BREPLACE FUEL INJECTOR ASSY
A
11SWITCH STEP BY NUMBER OF MISFIRE CYLINDER(REFER RESULT OF STEP 4)

If the result of step 4 is º1 or 2 cylindersº, proceed to A.

If the result of step 4 is ºmore than 3 cylindersº, proceed to B. BCHECK FOR INTERMITTENT PROBLEMS
A
12CHECK VALVE TIMING(CHECK FOR LOOSE AND JUMPING TEETH)
NGADJUST VALVE TIMING
OK
13CHECK FUEL PRESSURE(LOW PRESSURE) (See page 11±33)
NG CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK

03−1 6
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS Supplement (RM1045E) Part Tightened
ft
lbf
kgf
cm
N
m
Intake manifold x Cylinder head2120915
Power steering idle pulley bracket x Cylinder head
(See page 14 −108) Bolt A
Bolt B
72
39734
39853
29
Intake manifold insulator No. 1 x Intake manifold5.05144 in.
lbf
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe x injection pump With SST
Without SST
31
34316
34723
25
Nozzle leakage pipe No.2 x Cylinder head cover sub −assy8.89078 in.
lbf
Nozzle leakage pipe No.2 x Cylinder head8.89078 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2120915
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub −assy x Cylinder head2120915
Exhaust manifold x Cylinder head4747434
EGR pipe sub −assy x Cylinder head Bolt
Nut37
25375
25027
18
Vacuum pump oil pipe x Cylinder block Bolt Nut21
8.8214 9015
78 in.
lbf
Vacuum transmitting pipe No. 2 x Manifold converter
For nut With SST
Without SST
For bolt
27
30
25275
306
25520
22
18
Vacuum transmitting pipe No. 1 x Manifold converter
For nut With SST Without SST
For bolt
27
30
25275
306
25520
22
18
Exhaust gas temperature sensor x Manifold converter With SST
Without SST27
30275
30620
22
Exhaust gas temperature sensor x Vacuum transmitting pipe No. 26.46557 in.
lbf
Oil filter bracket x Oil pan sub −assy3434725
V −ribbed belt tensioner bracket x Cylinder block2020415
V −ribbed belt tensioner assy x Oil pump3131623
Generator bracket No.1 x Cylinder block3737727
Idler pulley Sub −assy x V −ribbed belt tensioner assy4040830
Engine mounting bracket RR x Engine mounting insulator RR6465347
Engine mounting bracket FR x Engine mounting insulator FR6465347
Drive shaft bearing bracket x Cylinder block6465347
Rear end plate x Cylinder block8.48674 in.
lbf
Flywheel x Crankshaft7172052
Engine mounting member sub −assy center x Body4545933

05−92
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
8 CHECK AIR INDUCTION SYSTEM
(a) Check for vacuum leaks in the air induction system.
NG REPAIR OR REPLACE AIR INDUCTION SYSTEM
OK
9 CHECK FUEL PRESSURE(LOW PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP,
PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
1 0 CHECK FUEL PRESSURE(HIGH PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP, FUEL
PRESSURE SENSOR, WIRING AND FUEL
LEAKAGE
OK
11 CONFIRM IF ANY MISFIRING DTCS WERE PRESENT AT STEP 1
(a) Misfiring DTC P0301, P0302, P0303 and/or P0304 was present at step 1.
NO REPLACE HEATED OXYGEN SENSOR
YES
1 2 REPLACE FUEL INJECTOR ASSY (See page 11−1 3)
HINT:
If one or more the misfiring DTCs P030 1, P0302, P0303 and/or P0304 were present at step 1, replace the
injector(s) mounted on the misfiring cylinder(s) that is referred by the DTC(s) with normal injector(s).
GO
13 PERFORM CONFIRMATION DRIVING PATTERN
HINT:
Clear all DTCs prior to performing the confirmation driving pattern.
GO

05−1 52
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
11 SWITCH STEP BY NUMBER OF MISFIRE CYLINDER(REFER TO RESULT OF STEP
4)
S If the result of step 4 is ” 1 or 2 cylinders”, proceed to A.
S If the result of step 4 is ”more than 3 cylinders”, proceed to B.
B CHECK FOR INTERMITTENT PROBLEMS
A
1 2 CHECK VALVE TIMING(CHECK FOR LOOSE AND JUMPED TOOTH OF TIMING
BELT)
NG ADJUST VALVE TIMING
OK
1 3 CHECK FUEL PRESSURE(LOW PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP,
PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
1 4 CHECK FUEL PRESSURE(HIGH PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP, FUEL
PRESSURE SENSOR, WIRING AND FUEL
LEAKAGE
OK

−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
05 −1 07
AVENSIS Supplement (RM 1045E)
10 CHECK WHETHER MISFIRE IS OCCURRED OR NOT BY MONITORING DTC AND
DATA LIST
NG PERFORM TROUBLESHOOTING FOR MISFIRE
(See page 05 −1 46)
OK
11 CHECK AIR INDUCTION SYSTEM
(a) Check for vacuum leaks in the air induction system.
NG REPAIR OR REPLACE AIR INDUCTION SYSTEM
OK
1 2 CHECK FUEL PRESSURE(LOW PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP,
PRESSURE REGULATOR, FUEL PIPE LINE AND
FILTER
OK
1 3 CHECK FUEL PRESSURE(HIGH PRESSURE) (See page 11− 4)
NG CHECK AND REPLACE FUEL PUMP, FUEL
PRESSURE SENSOR, WIRING AND FUEL
LEAKAGE
OK
1 4 CHECK FOR EXHAUST GAS LEAKS
NG REPAIR OR REPLACE EXHAUST GAS
LEAKAGE POINT (See Page 15− 2)
OK
1 5 CONFIRM IF ANY MISFIRING DTCS WERE PRESENT AT STEP 1
(a) Misfiring DTC P0301, P0302, P0303 and/or P0304 was present at step 1.
NO REPLACE HEATED OXYGEN SENSOR
YES

05I7H−01
−
DIAGNOSTICS ECD SYSTEM (1CD −FTV)(From September, 2003)
05 −27 1
AVENSIS Supplement (RM 1045E)
BASIC INSPECTION
When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the
possible circuits considered as causes of the problem. In many cases, by carrying out the basic engine check
shown in the following flowchart, the location causing the problem can be found quickly and efficiently. There-
fore, using this check is essential in the engine troubleshooting.
1 CHECK BATTERY VOLTAGE
NOTICE:
Carry out this check with the engine stopped and ignition switch OFF.
OKNG
Voltage11 V or moreLess than 11 V
NG CHARGE OR REPLACE BATTERY
OK
2 CHECK IF ENGINE WILL CRANK
NG PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05 −282
OK
3 CHECK AIR FILTER
(a) Visually check if the air filter is not contaminated with dirt or oil. NG CLEAN OR REPLACE
OK
4 CHECK FUEL QUALITY
(a) Check that only diesel fuel is used.
(b) Check that the fuel does not contain any impurity. NG REPLACE FUEL
OK
5 CHECK ENGINE OIL (See page 17− 9)
NG ADD OR REPLACE
OK

A91221
Common Rail System Diagram (1CD−FTV Fuel System):
Sensors ECM EDU
Common Rail
Fuel Pressure SensorPressure Discharge
Valve
Supply Pump Assy
Suction Control Valve
Fuel TankMain
Injector
Fuel Filter
: High−pressurized Area
Exhaust Fuel
Addition Injector
Exhaust Port
To DPNR
Catalytic
Converter 05−260
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
3. COMMON RAIL SYSTEM DESCRIPTION
(a)COMMON RAIL SYSTEM:
The common rail system stores high−pressurized fuel supplied from the supply pump in the common rail and
injects it using the injectors. Fuel injection timing and fuel injection volume are regulated by the ECM; it pro-
vides an electric current to the solenoid valve of the injector with the EDU to regulate them.
By storing high−pressurized fuel produced in the supply pump in the common rail, this system can always
offer stable fuel injection pressure regardless of the engine speed and engine load, even if a driving speed
is low. In addition, this system uses the injector that opens and closes its fuel passage with the Two−Wa y
Valve (TWV) therefore both the fuel injection time and volume are precisely regulated by the ECM.
The ECM monitors internal fuel pressure of the common rail with the fuel pressure sensor and commands
the supply pump to supply fuel to obtain a target internal pressure, approximately 30 to180 MPa (306 to
1,835 kgf/cm
2, 4,351to 26,106 psi). The ECM opens and closes the pressure discharge valve to improve
controllability for the common rail internal fuel pressure.
This system has two split fuel injections. It performs ”pilot−injection” as subsidiary fuel injection prior to the
main fuel injection to make combustion soft, and this helps to reduce engine vibration and noise.

100LY−01
A84695
Mass Air Flow
Meter Connector
N·m (kgf·cm, ft·lbf) : Specified torqueEngine Cover Sub−assy
No. 1
9.0 (92, 80 in.
lbf)
VSV
Connector Fuel Vapor Feed
Hose
Clip
Engine Room Cover Side
Radiator Support Opening Cover
Clip
Retainer
x2
x4
1.5 (15, 13 in.
lbf)
Air Cleaner Filter
Element Sub−assy x2
Air Cleaner Cap
Sub−assy
− ENGINE CONTROL SYSTEMKNOCK SENSOR (2AZ−FSE)
10−11
AVENSIS Supplement (RM1045E)
KNOCK SENSOR (2AZ−FSE)
COMPONENTS

A81620
(a)(c)
(c)
(b)
(f)
(g)
(d)
(h)
Air Cleaner Clamp
(e)
A84698
(a)
(b)
(c)
A84699
(d)
(e)
(e)
(e)
(e)
A84700
(f)
(f)
(f)
(f)
− ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (2AZ−FSE)
10−9
AVENSIS Supplement (RM1045E)
6. REMOVE AIR CLEANER CAP SUB−ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV connector.
(c) Remove the 2 wiring harness clamps.
(d) Disconnect the ventilation hose.
(e) Disconnect the fuel vapor feed hose No. 1.
(f) Disconnect the fuel vapor feed hose No. 2.
(g) Loosen the hose clamp bolt.
(h) Raise the air cleaner clamp up, then the slide it to the air
cleaner cap.
(i) Remove the air cleaner cap together with the air cleaner
hose No. 1.
(j) Remove the air cleaner filter element.
7. REMOVE THROTTLE BODY ASSY
(a) Disconnect the throttle control motor connector.
(b) Remove the bolt.
(c) Unfasten the clip, then remove the wiring harness protec-
tor.
(d) Remove the bolt, then remove the ground terminal.
(e) Remove the 4 bolts, then remove the throttle body brack-
et.
(f) Remove the 4 bolts, then remove the throttle body.
(g) Remove the gasket from the intake manifold.