power steering TOYOTA AVENSIS 2005 Service Repair Manual

022LX±01
± PREPARATIONDIAGNOSTICS
02±1
AVENSIS REPAIR MANUAL (RM1018E)
DIAGNOSTICS
PREPARATION
SST
09243±00020Idle Adjusting Screw WrenchSFI SYSTEM(1AZ±FE)
09843±18040Diagnosis Check Wire No.2AIR CONDITIONING SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
SUPPLEMENTAL RESTRAINT
SYSTEM
SFI SYSTEM(1AZ±FE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
09992±00242Turbocharger Pressure GaugeECD SYSTEM(1CD±FTV)
Recomended Tools
09082±00040TOYOTA Electrical TesterCOMBINATION METER
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)

02±2
± PREPARATIONDIAGNOSTICS
AVENSIS REPAIR MANUAL (RM1018E)
(09083±00150)Test Lead SetAIR CONDITIONING SYSTEM
ABS WITH EBD SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
MULTIPLEX COMMUNICATION
SYSTEM
ENGINE IMMOBILISER SYSTEM
ABS WITH EBD & BA & TRC & VSC
SYSTEM
WIRELESS DOOR LOCK CONTROL
SYSTEM
COMBINATION METER
KEY REMINDER WARNING SYSTEM
POWER DOOR LOCK CONTROL
SYSTEM
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)
09082±00050TOYOTA Electrical Tester SetPOWER DOOR LOCK CONTROL
SYSTEM
(09083±00150)Test Lead SetAIR CONDITIONING SYSTEM
ABS WITH EBD SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
MULTIPLEX COMMUNICATION
SYSTEM
ENGINE IMMOBILISER SYSTEM
ABS WITH EBD & BA & TRC & VSC
SYSTEM
WIRELESS DOOR LOCK CONTROL
SYSTEM
COMBINATION METER
KEY REMINDER WARNING SYSTEM
POWER DOOR LOCK CONTROL
SYSTEM
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)

± INTRODUCTIONTERMS
01±43
AVENSIS REPAIR MANUAL (RM1018E) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

01±38
± INTRODUCTIONTERMS
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Camshaft
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
DVDDigital Versatile Disc
EBDElectric Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECTElectronic Control Transmission
ECUElectronic Control Unit
EDElectro±Deposited Coating
EDUElectronic Driving Unit
EDICElectric Diesel Injection Control
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
EGR±VMEGR±Vacuum Modulator
ELREmergency Locking Retractor
EMPSElectric Motor Power Steering
ENGEngine
ESAElectronic Spark Advance
ETCS±iElectronic Throttle Control System±intelligent
EVAPEvaporative Emission Control
EVPEvaporator
E±VRVElectric Vacuum Regulating Valve
EXExhaust
FEFuel Economy
FFFront±Engine Front±Wheel±Drive
F/GFuel Gauge
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
F/WFlywheel
FW/DFlywheel Damper
FWDFront±Wheel±Drive
GASGasoline
GNDGround
GPSGlobal Positioning System
HACHigh Altitude Compensator
H/BHatchback

01±40
± INTRODUCTIONTERMS
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension

± INTRODUCTIONTERMS
01±41
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
TFTToyota Free±Tronic
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRCTraction Control System
TURBOTurbocharge
TWCThree±Way Catalyst
U/DUnderdrive
U/SUndersize
VCVVacuum Control Valve
VENTVentilator
VINVehicle Identification Number
VPSVariable Power Steering
VSCVehicle Stability Control
VSVVacuum Switching Valve
VTVVacuum Transmitting Valve
VVT±iVariable Valve Timing±intelligent
w/With
WGNWagon
W/HWire Harness
w/oWithout
WU±TWCWarm Up Three±way Catalytic Converter
WU±OCWarm Up Oxidation Catalytic Converter
1stFirst
2ndSecond
2WDTwo Wheel Drive Vehicle (4 x 2)
3rdThird
4thFourth
4WDFour Wheel Drive Vehicle (4 x 4)
4WSFour Wheel Steering System
5thFifth

010B6±13
±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±21
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
There are many ECU controlled systems used in the AVENSIS. In general, ECU controlled system are con-
sidered to be very intricate and require a high level of technical knowledge an\
d expert skill to troubleshoot.
The fact is, however, that if you proceed by inspecting the circuits one by one, troubleshoo\
ting of these sys-
tems is not complex. If you have adequate understanding of the system and ba\
sic knowledge of electricity,
the problem can be accurately diagnosed and fixed. This manual is design\
ed based on the above principle
to help service technicians perform accurate and effective troubleshooting, and is compiled for the following
major ECU controlled systems:
The troubleshooting procedures are described on the following pages.
SystemPage
1. SFI System [1ZZ±FE, 3ZZ±FE]05±1
2. SFI System [1AZ±FE]05±143
3. SFI System [1AZ±FSE]05±290
4. ECD System [1CD±FTV]05±523
5. ABS with EBD System05±696
6. ABS with EBD & BA & TRC & VSC System05±752
7. Electronic Controlled Automatic Transmission [ECT] [U241 (1AZ±FE)]05±856
8. Electronic Controlled Automatic Transmission [ECT] [U241 (1AZ±FSE)]05±915
9. Electronic Controlled Automatic Transmission [ECT] [U341]05±980
10.Electronic Motor Power Steering System05±1042
11. Air Conditioning System05±1088
12.Combustion Type Power Heater System05±1161
13.Supplemental Restraint System05±1181
14.Audio System05±1393
15.Navigation System05±1435
16.Combination Meter05±1497
17.Power Door Lock Control System05±1534
18.Wireless Door Lock Control System05±1568
19.Key Reminder Warning System05±1586
20.Engine Immobiliser System05±1599
21.Theft Deterrent System05±1627
22.Multiplex Communication System05±1654
23.Cruise Control System05±1697
FOR USING HAND±HELD TESTER

Before using the tester, the tester's operator manual should be read thoroughly.

If the tester cannot communicate with the ECU controlled systems when you \
have connected the cable
of tester to the DLC3, turned the ignition switch ON and operated the test\
er, there is a problem on the
vehicle side or tester side.
(1) If the communication is normal when the tester is connected to another veh\
icle, inspect the diag-
nosis data link line (Bus
line) or ECU power circuit of the vehicle.
(2) If the communication is still impossible when the tester is connected to a\
nother vehicle, the prob- lem is probably in the tester itself, so perform the Self Test procedures outlined in the Tester Oper-
ator 's Manual.

022KE±01
± PREPARATIONPOWER STEERING
02±45
AVENSIS REPAIR MANUAL (RM1018E)
POWER STEERING
PREPARATION
SST
09023±12700Union Nut Wrench 17mmRACK & PINION POWER STEERING
GEAR ASSY
VANE PUMP ASSY(1CD±FTV)
09249±63010Torque Wrench AdaptorVANE PUMP ASSY(AZ Series)
09521±24010Rear Axle Shaft PullerSTEERING GEAR ASSY
RACK & PINION POWER STEERING
GEAR ASSY
09612±00012Rack & Pinion Steering Rack
Housing StandSTEERING GEAR ASSY
09616±00011Steering Worm Bearing Adjusting
SocketSTEERING GEAR ASSY
09630±00014Power Steering Gear Housing
Overhaul Tool SetVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
(09631±00132)Vane Pump BracketVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
09922±10010Variable Open WrenchSTEERING GEAR ASSY
09950±60010Replacer SetVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
(09951±00280)Replacer 28VANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
09950±70010Handle SetVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
(09951±07100)Handle 100VANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)

02±46
± PREPARATIONPOWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09025±00010Torque Wrench (30 kgf±cm)STEERING GEAR ASSY
RACK & PINION POWER STEERING
GEAR ASSY
VANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
09090±04020Engine Sling DeviceSTEERING GEAR ASSY
RACK & PINION POWER STEERING
GEAR ASSY
09905±00012Snap Ring No.1 ExpanderVANE PUMP ASSY(1CD±FTV)
VANE PUMP ASSY(AZ Series)
Equipment
Caliper gaugeVane pump assy
Belt tension gaugeVane pump assy
Vernier calipersVane pump assy
Feeler gaugeVane pump assy
MicrometerVane pump assy
Torque wrench

022JS±01
02±44
± PREPARATIONSTEERING COLUMN
AVENSIS REPAIR MANUAL (RM1018E)
STEERING COLUMN
PREPARATION
SST
09616±00011Steering Worm Bearing Adjusting
SocketSTEERING COLUMN ASSY
09950±50013Puller C SetSTEERING COLUMN ASSY
(09951±05010)Hanger 150STEERING COLUMN ASSY
(09952±05010)Slide ArmSTEERING COLUMN ASSY
(09953±05020)Center Bolt 150STEERING COLUMN ASSY
(09954±05021)Claw No.2STEERING COLUMN ASSY
Recomended Tools
09025±00010Torque Wrench (30 kgf±cm)STEERING COLUMN ASSY
09042±00010Torx Socket T30STEERING COLUMN ASSY
09070±20010Moulding RemoverSTEERING COLUMN ASSY
POWER STEERING ECU ASSY
EQUIPMENT
Torque wrench