2002 TOYOTA AVENSIS check engine

A64328
2 to 7 mm0 to 2 mm
A78274
Upward90

Clamp
Bolt
±
INTAKE TURBOCHARGER SUB±ASSY(1CD±FTV)
13±17
AVENSIS REPAIR MANUAL (RM1018E)
41.INSTALL INTERCOOLER AIR HOSE
(a)Install the air hose and hose clamps as shown in the il-
lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
42.INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
43.INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
44.INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
45.ADD ENGINE COOLANT(See page 16±44)
46. CHECK ENGINE OIL LEVEL
47.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
48. CHECK FOR ENGINE OIL LEAKS
49.CHECK FOR FUEL LEAKS(See page 11±60)
50. CHECK FOR EXHAUST GAS LEAKS

010B8±08
D25086
WRONG
CORRECT
D25087
Looseness of Crimping
Core Wire
Terminal
Deformation
Pull Lightly 01±32
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
ELECTRONIC CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS
(1) Unless stated, all resistance is measured at an ambient temperature of 20C (68F). As the re-
sistance may be outside the specifications if measured at high temperatures immediately after
the vehicle has been running, measurements should be made when the engine has cooled
down.
(b) HANDLING OF CONNECTOR
(1) When removing the connector with lock, press the
connector in the direction of the engagement and
remove the lock by lightly pressing the lock claw.
(2) When removing the connector, do not hold the har-
ness, but hold the connector.
(3) Before connecting the connector, check that there
is no deformation, damage or missing terminals.
(4) The connector with a lock should be securely con-
nected until it makes a ºclickº sound.
(5) When checking the connector with a Toyota electri-
cal tester, check it from the backside (harness side)
of the connector using a mini test lead.
NOTICE:

As a water proof connector cannot be checked from
the backside, check by connecting the sub±harness.

Do not damage the terminals by moving the inserted
tester needle.
(c) CONNECTOR CHECKING POINTS
(1) Checking when the connector is connected:
By holding the connector, check the inserted condi-
tion and locking efficiency (engaged condition).
(2) Checking when the connector is removed:
Check by lightly pulling the wire harness (missing
terminal, terminal crimping condition, core wire
break).
Check visually for any rust, metal particles, water
and bent terminals (rust, mixing of foreign object,
terminal deformation).
NOTICE:
When testing a gold±plated female terminal, always use a
gold±plated male terminal.

IN0383
Example
Ground
IN0384
Ground ECU Side
W/H Side
Ground
01±36± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
4. CHECK AND REPLACE ECU
NOTICE:

Start an inspection of the connector from the back-
side of the connector on the wire harness side with
the connector connected to the ECU.

When no measurement condition is specified, per-
form the inspection with the engine stopped and also
the ignition switch ON.
(a) First check the ECU ground circuit. If it is faulty, repair it.
If it is normal, the ECU could be faulty. In this case, re-
place the ECU with one that functions normally and check
if the symptoms appear.
(1) Measure the resistance between the ECU ground
terminal and body ground.
Resistance: 1
or less
(2) Disconnect the ECU connector, check the ground
terminals on the ECU side and wire harness side for
bends and check the contact pressure.

010B7±13
01±22± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic
procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods
for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning trouble-
shooting of that circuit.
1 Vehicle brought to workshop
2 Customer problem analysis
(a) Ask the customer about the conditions and environment when the problem occurred.
3 Symptom confirmation and DTC (and freeze frame data) check
(a) Check the battery positive voltage.
Voltage: 11 ± 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions, and check for DTCs according to the related chart.
OK Go to step 5
NG
4 DTC chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the DTC chart.
Go to step 6
5 Problem symptoms chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the problem symptoms table.
6 Circuit inspection or parts inspection
(a) Confirm the circuit for the system or the part which should be checked using the problem symptoms
table or the results obtained in step 4.
7 Repair
(a) Repair the affected system or part in accordance with the instructions in step 6.

± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±25
AVENSIS REPAIR MANUAL (RM1018E)
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT:

The diagnostic system in AVENSIS has various functions. The first function is the Diagnostic Trouble
Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in
the ECU memory. Another function is the Input Signal Check, which checks if the signals from various
switches are sent to the ECU correctly. By using these check functions, it is possible to quickly narrow
down potential problem areas and troubleshooting can be performed effectively. The diagnostic func-
tions are incorporated in the following systems in the AVENSIS.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Diagnostic Test
Mode (Active Test)
SFI System (1AZ±FE/1AZ±FSE, 1ZZ±FE/3ZZ±FE)

(with Check Mode)


ECD System (1CD±FTV)

(with Check Mode)


ABS with EBD System



ABS with EBD & BA & TRC & VSC System



Electronically Controlled Automatic Transmission [ECT]

(with Check Mode)

Air Conditioning System


Supplemental Restraint System

Audio System

Power Door Lock Control System


Wireless Door Lock Control System

Key Reminder Warning System

Engine Immobiliser System


Theft Deterrent System


Multiplex Communication System

Cruise Control System



In the DTC check, it is very important to determine whether the problem indicated by the DTC is still
occurring or has occurred in the past but returned to normal at present. In addition during the problem
symptom check, it a check must be made on whether the malfunction indicated by the DTC is directly
related to the problem symptom or not. For this reason, the DTC should be checked before and after
symptom confirmation to determine the current conditions. If this is not done, it may, depending on the
case, result in unnecessary troubleshooting for systems that are operating normally. This would make
more difficult to detect the problem area or to try to repair irrelevant areas. Therefore, always follow
the procedures in the correct order and perform the DTC check.

A flow chart showing how to proceed with troubleshooting using the diagnostic trouble code (DTC)
check is shown the this page. This flow chart shows how to utilize the DTC check effectively. Then,
by carefully checking the results, this chart indicates how to proceed either to the DTC troubleshooting
or to the troubleshooting of the problem symptoms table.
1 DTC check
2 Make a note of DTCs displayed and then clear the memory
3 Symptom confirmation

D25083
Vibrate Slightly
Shake Slightly
Vibrate
Slightly
D25084
Malfunction
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±27
AVENSIS REPAIR MANUAL (RM1018E)
SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no symptoms occurs. In such cases, a thorough customer
problem analysis must be carried out. Then the same or similar conditions and environment in which the
problem occurred in the customer's vehicle should be simulated. No matter how much experience a techni-
cian has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms,
he 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 when the engine is hot or when the vehicles is at a standstill. Since vibration, heat or water
penetration (moisture) is a likely cause for the problem which is difficult to reproduce, the symptom simulation
tests introduced here are effective measures in a point that the external causes are applied to the vehicle
in a stationary condition.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms should be confirmed, and the problem area or parts
must also be discovered. To do so, reduce the possible problem circuits according to the symptoms before
starting this type of test and have the hand±held tester connected beforehand. After that, carry out the symp-
tom simulation test, judging whether the circuit being tested is defective or normal and also confirming the
problem symptoms at the same time. Refer to the problem symptoms table of each system to narrow down
the possible causes of the symptom.
1. VIBRATION METHOD: When vibration seems to be
the major cause.
(a) PART AND SENSOR
(1) Apply slight vibration with your finger to the part of
the sensor considered to be the problem cause and
check whether the malfunction occurs.
HINT:
Applying strong vibration to relays may result in open relays.
(b) CONNECTORS
(1) Slightly shake the connector vertically and horizon-
tally.
(c) WIRE HARNESS
(1) Slightly shake the wire harness vertically and hori-
zontally.
The connector joint and fulcrum of the vibration are
the major areas that should be checked thoroughly.
2. HEAT METHOD: If the problem seems to occur when
the area in question is heated.
(a) Heat the component that is the possible cause of the mal-
function with a hair dryer or similar object. Check if the
malfunction occurs.
NOTICE:

Do not heat the components to more than 60C
(140F) (Temperature is limited to keep the compo-
nents from being damaged).

D25085
B02389
ON 01±28
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)

Do not apply heat directly to the parts in the ECU.
3. WATER SPRINKLING METHOD: When the malfunc-
tion seems to occur on a rainy day or in high±humid-
ity.
(a) Sprinkle water onto the vehicle and check if the malfunc-
tion occurs.
NOTICE:

Never sprinkle water directly onto the engine
compartment, but indirectly change the temperature
and humidity by spraying a mist of water onto the ra-
diator front surface.

Never apply water directly onto the electronic compo-
nents.
HINT:
If a vehicle is subject to water leakage, the leaking water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, this factor must also be considered.
4. OTHERS: If the malfunction seems to occur when
electrical load is excessive.
(a) Turn on all the electrical equipment including the heater
blower, headlights, rear window defogger, etc., and check
if the malfunction occurs.

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.