check oil TOYOTA AVENSIS 2005 Service Repair Manual

010LF±01



 

D25016
± INTRODUCTIONREPAIR INSTRUCTION
01±5
AVENSIS REPAIR MANUAL (RM1018E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1Looks
Always wear a clean uniform.

Hat and safety shoes must be worn.
2Vehicle protection
Set a grill cover, fender cover, seat cover and floor mat before starting operation.
3Safe operation

When working with 2 or more persons, be sure to check the safety of one another.

When working with the engine running, pay attention to providing ventilation for exhaust fumes in the work-
shop.

When working with high±temperatures, rotating, moving or vibrating parts, be careful not to burn or injure
yourself.

When jacking up the vehicle, be sure to support the specified location with a safety stand.

When lifting up the vehicle, use safety equipment.
4Preparation of tools and
measuring gauge
Before starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations

Diagnose with a thorough understanding of the trouble condition and perform effective operation.

Before removing the parts, check the general condition of the assembly, and for deformation and damage.

When the structure is complicated, take a notes or make matchmarks as not to make mistakes that affect the
function of the parts.

Clean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts

Place the removed parts in the correct order to avoid mixing them up or making them dirty.

As for non±reusable parts such as gaskets, O±rings, and self±locking nuts, replace them with new ones
following the instructions in this manual.

Organize the parts that were replaced in a box and show them to the customer.

D26613
Example:
D25080
Negative (±)
Terminal
± INTRODUCTIONREPAIR INSTRUCTION
01±15
AVENSIS REPAIR MANUAL (RM1018E)
(8) Oil or water should not be put on the front seat outer belt and the front seat outer belt should be
cleaned with the appropriate detergents.
(i) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved in a collision where the SRS has deployed.
(2) The connectors to the airbag sensor assembly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted to the floor, it could cause an undesired ignition of the supple-
mental restraint system.
(3) Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº
position and the negative (±) terminal cable is disconnected from the battery, even if only loosen-
ing the set bolts of the airbag sensor assembly.
(j) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All connec-
tors in the system are a standard yellow color. If the SRS wire harness becomes disconnected
or the connector becomes broken due to an accident, etc., repair or replace it.
3. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (±) terminal cable beforehand in
order to prevent it from shorting and burning out.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF, and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal.
(3) When the battery terminal cable is removed, the
memories of the clock, radio, DTCs, etc. are erased.
So before removing it, check them and make a note
of their settings.
(4) When the battery negative (±) terminal cable is dis-
connected, memories of various systems are
erased. Therefore, refer to the PRE±CHECK for
each system to make sure whether or not the sys-
tem needs to be initialized after the battery negative

± PREPARATIONENGINE MECHANICAL
02±11
AVENSIS REPAIR MANUAL (RM1018E)
(09330±00030)PinPARTIAL ENGINE ASSY(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
09520±01010Drive Shaft Remover AttachmentENGINE REAR OIL SEAL(1CD±FTV)
09520±24010Differential Side Gear Shaft
PullerENGINE REAR OIL SEAL(1CD±FTV)
(09520±32040)Shocker SetENGINE REAR OIL SEAL(1CD±FTV)
09628±62011Boll Joint PullerENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09670±00010Front Crossmember Guide ToolENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09817±33190Sensor Socket WrenchPARTIAL ENGINE ASSY(1AZ±FE)
PARTIAL ENGINE ASSY(1AZ±FSE)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
09843±18020Diagnosis Check WireENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
09843±18040Diagnosis Check Wire No.2ENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1CD±FTV)
ENGINE(1ZZ±FE/3ZZ±FE)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
09930±00010Drive Shaft Nut ChiselENGINE REAR OIL SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)

02±14
± PREPARATIONENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
(09962±01000)Variable Pin Wrench Arm AssyTIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
(09963±01000)Pin 10TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09992±00025Cylinder Compression Check Gauge
SetENGINE(1CD±FTV)
(09992±00121)No. 4 AttachmentENGINE(1CD±FTV)
(09992±00211)Gauge AssyENGINE(1CD±FTV)
09992±00242Turbocharger Pressure GaugeVALVE CLEARANCE(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
09992±00500Compression Gauge AttachmentENGINE(1AZ±FE)
ENGINE(1AZ±FSE)
ENGINE(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)

03±20
± SERVICE SPECIFICATIONSENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)Part Tightenedft
lbf kgf
cm N
m
Injection pipe, Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe x Injector
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Injection pipe clamp x Intake manifold5.05144 in.
lbf
Fuel inlet pipe x Common rail
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Fuel inlet pipe x injection pump
Used pipe using SST
Used pipe not using SST
New pipe using SST
New pipe not using SST
42
46
31
34428
469
316
34731
34
23
25
Nozzle leakage pipe No.2 x Cylinder head Check valve
Bolt21
8.8214
9015
78 in.
lbf
Vacuum pump x Cylinder head2121415
EGR valve assy x Cylinder head1818413
Intake air connector with diesel throttle body x Intake manifold2121415
Water inlet x Cylinder block8.89078 in.
lbf
Water outlet sub±assy x Cylinder head2121415
Exhaust manifold x Cylinder head4747935
EGR pipe sub±assy x Cylinder head Bolt
Nut37
25375
25027
18
Oil filter bracket x Oil pan sub±assy3434725
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
Front suspension crossmember sub±assy x Rear engine mounting bracket8788764
Front suspension crossmember sub±assy x Front engine mounting bracket5253038
Front suspension crossmember sub±assy x Body1331,35698
Front suspension member brace x Front suspension crossmember sub±assy1331,35698
Front suspension member brace x Body8081659
Return tube sub±assy x Body8.08271 in.
lbf
Engine mounting insulator RH x Body5253038
Engine mounting bracket LH x Engine mounting insulator LH8081659
Injector driver x Engine mounting insulator RH5.05144 in.
lbf
Engine wire x Body8.48574 in.
lbf
Air tube No.2 x Manual transaxle2525518
Relay box x Radiator assy5.35446 in.
lbf
Fuel filter assy x Fuel filter support1817813

0505L±04
05±22
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can\
not be confirmed in the basic inspection, proceed to this problem symptoms \
tables and troubleshoot accord-
ing to the numbered order given below.
SymptomSuspect AreaSee page
Engine does not crank (Does not start)1. Starter and starter relay
2. Neutral start switch circuit*19±1

No initial combustion (Does not start)
1. ECM power source circuit
2. Ignition coil (w/ Igniter) circuit
3. Fuel pump control circuit
4. Fuel system05±124
05±103
05±131
11±1
No complete combustion (Does not start)
1. Fuel pump control circuit
2. Ignition coil (w/ Igniter) circuit
3. Fuel system05±131
05±103
11±1
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Ignition coil (w/ Igniter)
5. Spark plug
6. Compression
7. Fuel system05±135
05±100
05±131
05±10318±3
14±111±1
Cold engine (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Fuel system
5. Ignition coil (w/ Igniter)
6. Spark plug05±135
05±100
05±131 11±1
05±103 18±3
Hot engine (Difficult to start)
1. Starter signal circuit
2. ISC valve circuit
3. Fuel pump control circuit
4. Fuel system
5. Ignition coil (w/ Igniter)
6. Spark plug05±135
05±100
05±131 11±1
05±103 18±3
Incorrect first idle (Poor idling)1. ISC valve circuit05±100
High engine idle speed (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Neutral start switch circuit*05±100
05±124

Low engine idle speed (Poor idling)
1. ISC valve circuit
2. Neutral start switch circuit*
3. Fuel pump control circuit
4. Fuel system05±100

05±131 11±1
Rough idling (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Fuel pump control circuit05±100
05±124
05±131
Hunting (Poor idling)
1. ISC valve circuit
2. ECM power source circuit
3. Fuel pump control circuit05±100
05±124
05±131
Hesitation/Poor acceleration (Poor drivability)
1. Fuel system
2. Fuel pump control circuit
3. Ignition coil (w/ Igniter) circuit11±1
05±131
05±103
Muffler explosion, after fire (Poor drivability)
1. Ignition coil (w/ Igniter) circuit
2. Spark plug
3. Fuel system05±103 18±3
11±1
Surging (Poor drivability)
1. Fuel pump control circuit
2. Spark plug
3. Fuel system05±131 18±3
11±1

A18294
#40#30#20#10E01
ECM Connector
E13
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
05±77
AVENSIS REPAIR MANUAL (RM1018E)
5CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER
(See page 18±1)
OKREPLACE SPARK PLUG
NG
6CHECK HARNESS AND CONNECTOR OF MISFIRING CYLINDER(IGNITION COIL ± ECM) (See page 05±103)
OKREPLACE IGNITION COIL ASSY (THEN CON- FIRM THAT THERE IS NO MISFIRE)
NG
REPAIR OR REPLACE HARNESS OR CONNECTOR
7INSPECT ECM TERMINAL OF MISFIRING CYLINDER(#1, #2, #3 OR #4 VOLTAGE)
(a)Turn the ignition switch ON.
(b)Measure the voltage between the terminals of the E13 ECM connector.
Standard:
Symbols (Terminal No.)Specified condition
#10 (E13±1) ± E01 (E13±7)
#20 (E13±2) ± E01 (E13±7)8to14V#30 (E13±3) ± E01 (E13±7)8 to 14 V
#40 (E13±4) ± E01 (E13±7)
OKGo to step 10
NG
8INSPECT FUEL INJECTOR RESISTANCE OF MISFIRING CYLINDER (See page 11±8)
NG REPLACE FUEL INJECTOR ASSY
OK

A63991
ECM
C2
Camshaft Timing
Oil Control Valve
2
1
Y±B
W±G
OCV+
OCV±
15
14
E13
E13
05±112
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP1349VVT SYSTEM MALFUNCTION (BANK 1)
CIRCUIT DESCRIPTION
VVT system controls the intake valve timing to proper timing in response to\
driving condition.
The ECM controls the oil control valve (OCV) to make the intake valve timing properly, oil pressure regulated
by the OCV is supplied to the valiable valve timing (VVT) controller, and then the VVT controller changes
relative position between the camshaft and the crankshaft.
DTC No.DTC Detecting ConditionTrouble Area
P1349
Condition (a) or (b) continues with engine speed at 400 to
4,000 rpm after the engine is warmed up
(a)Valve timing does not change from the current valve timing
(b)Current valve timing is fixed
Valve timing

OCV

VVT controller assembly

ECM
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
Read freeze frame data using \f \b\f\f
 Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determi\
ning whether the vehicle was running
or stopped, the engine was warmed up or not, the air±fuel ratio was lea\
n or rich, etc. at the time of the mal-
function.
1CHECK VALVE TIMING (See page 14±49)
NGADJUST VALVE TIMING(See page 14±49)
OK
05C6F±01

A18294
OCV+OCV±
ECM Connector
E13
A58701A58701
OCV Signal Waveform1 m sec./Division 5 V/
Division
GND
(A)(A)(A)
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
05±113
AVENSIS REPAIR MANUAL (RM1018E)
2PERFORM ACTIVE TEST BY HAND±HELD TESTER(OPERATE OF OCV)
(a)Start the engine and warm it up.
(b)Connect the hand±held tester and select VVT from the ACTIVE TEST menu\
.
(c)Check the engine speed while operating the OCV by the hand±held teste\
r.
OCV is OFF: Normal engine speed
OCV is ON: Rough idle or engine stall
HINT:
DTC P1349 is also output when a foreign object is detected in some parts\
of the system in engine oil, and
then the system returns to normal in a short time. There is also no problem \
on the VVT as the oil filter should
catch the foreign object in engine oil.
OKVVT SYSTEM OK
NG
3INSPECT ECM(CHECK VOLTAGE)
(a)Turn the ignition switch ON.
(b)Check the waveform between terminals OCV+ and OCV± of the E13 ECM connector.
HINT:

The correct waveform is as shown on the left.

The waveform frequency (A) becomes longer as the en-
gine speed becomes higher.
NGCHECK AND REPLACE ECM (See page 01±32)
OK
4INSPECT CAMSHAFT TIMING GEAR ASSY (See page14±64)
NG REPLACE VVT CONTROLLER ASSEMBLY, AND THEN GO TO NEXT STEP
OK

05±114
±
DIAGNOSTICS SFI SYSTEM(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
5INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 10±3)
NGREPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY, AND THEN GO TO NEXT
STEP
OK
6CHECK OIL CONTROL VALVE FILTER(CHECK BLOCKAGE)
NGREPAIR OR REPLACE OIL CONTROL VALVE FILTER
OK
7PERFORM SIMULATION TEST(DTC CHECK)
(a)Clear the DTC (See page 05±5).
(b)Perform the simulation test.
(c)Check whether or not DTC P1349 is stored (See page 05±5). Result:
DTCProceed to
ºP1349º is output.A
ºP1349º is not output.B
HINT:
DTC P1349 is also output when a foreign object is detected in some parts\
of the system in engine oil, and
then the system returns to normal in a short time. There is also no problem \
on the VVT as the oil filter should
catch the foreign object in the engine oil.
BVVT SYSTEM OK
A
CHECK AND REPLACE ECM (See page 01±32)