1999 TOYOTA AVENSIS engine

1999 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jun. 15, 1999 01–990615–00
FOREWORD
This supplement has been prepared to provide information covering general se\
rvice repairs for the chassis
and body of the TOYOTA AVENSIS/CORONA which underwent changes in August, 1999.Applicable models: AT220, 221 series
ST220 series
CT220 series
CDT220 series
Pub. No.Manual NamePub. No.

A VENSIS/CORONA Chassis and Body Repair
ManualRM599E
2C Engine Repair Manual SupplementRM297E

4A–FE Engine Repair ManualRM296E
2C–T Engine Repair Manual SupplementRM494E

7A–FE Engine Repair ManualRM325E
2C–T, 2C–TE Engine Repair Manual SupplementRM612E

4A–FE Engine Repair Manual SupplementRM397E
1CD–FTV Engine Repair ManualRM697E

7A–FE Engine Repair Manual SupplementRM435E
A241L, A241E Automatic Transaxle Repair ManualRM177E

4A–FE, 7A–FE Engine Repair Manual SupplementRM611E
A245E Automatic Transaxle Repair ManualRM350E

3S–FE Engine Repair ManualRM395E
AVENSIS/CORONA Electrical Wiring DiagramEWD330Y

3S–FE Engine Repair Manual SupplementRM495E
AVENSIS/CORONA Electrical Wiring Diagram
SupplementEWD373F

3S–FE Engine Repair Manual SupplementRM609E
AVENSIS/CORONA New Car FeaturesNCF145E

1C, 2C, 2C–T Engine Repair ManualRM025E
AVENSIS/CORONA New Car Features SupplementNCF168E
All information in this manual is based on the latest product information at the time of\
publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
AZT 220 series
Manual Name
ZZT220, 221 series
For the service specifications and repair procedures of the above model othe\
r than those listed in this supple-
ment, refer to the following manuals.

INTRODUCTION
HOW TO USE THIS MANUAL IN–1. . . . . . . . . . . . .
GENERAL INFORMATION IN–1. . . . . . . . . . . . . . . . . .
IDENTIFICATION INFORMATION IN–3. . . . . . . . . .
VEHICLE IDENTIFICATION AND ENGINE SERIAL
NUMBER IN–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS IN–4. . . . . . . . . . . . . . . . .
GENERAL INFORMATION IN–4. . . . . . . . . . . . . . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS IN–7. .
FOR ALL OF VEHICLES IN–9. . . . . . . . . . . . . . . . . .
PRECAUTION IN–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS IN–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION IN–18. . . . . . . . . . . . . . . . . .
HOW TO PROCEED
WITH TROUBLESHOOTING IN–19. . . . . . . . . . . . . .
HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE IN–29. . . . . . . . . . . . . . .
TERMS IN–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS USED IN THIS MANUAL IN–34. . . .

IN06B–05
B02393
B A
B02403
4A–FE and 7A–FE engines 3S–FE engine 2C–T, 2C–TE and 1CD–FTV engines
– INTRODUCTIONIDENTIFICATION INFORMATION
IN–3
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped in the engine
compartment. This number has also been stamped on the
manufacturer ’s label.
A: Vehicle Identification Number
B: Manufacturer’s Label
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN0002
Example IN–6
– INTRODUCTIONREPAIR INSTRUCTIONS
(2) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on a vehicle raised on a jack alone, even for a small
job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission–related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step–down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20
C (68
F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.

IN–16
– INTRODUCTIONFOR ALL OF VEHICLES
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off and prolonged braking.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two–way radios and cellular telephones, observe
the following precautions.
(a) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic sys-
tem.
(b) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s
electronic systems. For details about ECU and sensors locations, refer to the section on the applicable
component.
(c) Do not wind the antenna feeder together with the other wiring as much as possible, also avoid running
the antenna feeder parallel with other wire harnesses.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install powerful mobile communications system.
4. FOR USING HAND–HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the hand–held tester, the hand–held tester’s operator manual should be read thor-
oughly.
Be sure to route all cables securely when driving with the hand–held tester connected to the
vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Two persons are required when test driving with the hand–held tester, one person to drive the
vehicle and the other person to operate the hand–held tester.

V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the mal-
function occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT:
Applying strong vibration to relays may result in open relays.
– INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN–23
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer’s vehicle. No matter how much experience a
technician has, or how skilled he or she may be, if he or she proceeds to troubleshoot without confirming
the problem symptoms he or she will tend to overlook something important in the repair operation and make
a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs
when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving,
etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condi-
tion or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for prob-
lem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in
that the external causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes of the symptom.


B02390
HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:3 WATER SPRINKLING METHOD:
(1)
(2)
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high–humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON HINT:
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
Do not heat to more than 60 C (140 F). (Temperature
is limited not to damage the components.)
Do not apply heat directly to parts in the ECU. (1)
(2)
Never sprinkle water directly into the engine compart-
ment, but indirectly change the temperature and hu-
midity by applying water spray onto the radiator front
surface.
Never apply water directly onto the electronic compo-
nents. NOTICE: IN–24
– INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN044–07
IN–34
– INTRODUCTIONTERMS
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti–Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
BACSBoost Altitude Compensation System
BATBattery
B/LBi–Level
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CDCompact Disc
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CRSChild Restraint System
CTRCenter
DCDirect Current
DIFF.Differential
DIFF. LOCKDifferential Lock
DLCData Link Connector
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
ECTElectronic Control Transmission
ECUElectronic Control Unit
EDUElectronic Driving Unit
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
ELREmergency Locking Retractor
E–VRVElectronic Vacuum Regulating Valve