2002 TOYOTA AVENSIS check engine

± 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)

030MV±02
03±42
± SERVICE SPECIFICATIONSBRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wheel nut1031,05076
Brake line union nut 10 mm
14 mm15
29155
29611
21
Brake booster clevis lock nut1919414
Brake master cylinder sub±assy x Brake booster assy2020415
Charcoal canister bracket x Body5.45548 in.
lbf
Brake booster assy x Body131309
Brake pedal support x Instrument panel reinforcement2424117
Brake pedale support x Brake pedal3737527
Brake pedale support x Body131309
Brake tube clamp x body5.45548 in.
lbf
Vacuum pump x Engine2121415
Vacuum pump union nut1414010
Vacuum pump check valve sub±assy x End cover7421454
Vacuum pump end cover x vacuum pump housing7.88069 in.
lbf
Front disc brake bleeder plug101027
Front brake cylinder mounting x Steering knuckle1021,04075
Front disc brake cylinder x Front disc brake cylinder mounting3030622
Front disc brake caliper x Flexible hose2929621
Rear disc brake bleeder plug101027
Rear disc brake cylinder mounting x Steering knuckle4747534
Rear disc brake cylinder x Rear disc brake cylinder mounting3030622
Rear disc brake caliper x Flexible hose2929621
Brake actuator x Brake actuator bracket
w/o VSC:
w/ VSC:7.0
4.771
4862 in.
lbf
42 in.
lbf
Front speed sensor wire harness clamp x shock absorber2929621
Brake actuator bracket x Body1919514
Front speed sensor x Steering knuckle8.08271 in.
lbf
Yawrate sensor bracket set bolt2121415
Yawrate sensor x Yawrate sensor bracket66153 in.
lbf
Yawrate sensor bracket x Body2121415

031GG±01
± SERVICE SPECIFICATIONSENGINE HOOD/DOOR
03±73
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE HOOD/DOOR
TORQUE SPECIFICATION
Part TightenedNmkgfcmftlbf
HOOD
Hood hinge x Hood1313310
Hood hinge x Body5.55649 in.lbf
Hood lock x Hood8.08271 in.lbf
FRONT DOOR
Door check x Body3030622
Door check x Door panel5.55646 in.lbf
Door frame sub±assy rear lower x Door panel8.08271 in.lbf
Door glass x Front door window regulator5.55649 in.lbf
Door hinge x Body2626519
Door hinge x Door panel2626519
Door lock x Door panel5.05144 in.lbf
Door lock striker x Body2323517
Door outside handle cover x Door panel7.07162 in.lbf
Door outside handle frame x Door panel4.04135 in.lbf
Outer view mirror x Door panel101027
Window regulator x Door panel8.08271 in.lbf
REAR DOOR
Door check x Body3030622
Door check x Door panel5.55649 in.lbf
Door hinge x Body2626519
Door hinge x Door panel2626519
Door lock x Door panel5.05144 in.lbf
Door lock striker x Body2323517
Door outside handle cover x Door panel4.04135 in.lbf
Door outside handle frame x Door panel7.07162 in.lbf
Window division bar sub±assy x Door panel5.55649 in.lbf
LAGGAGE COMPERTMENT DOOR
Back door striker assy x Body11.51208.0
Luggage compertment door x Hinge7.07062 in.lbf
Luggage lock assy x Luggage compertment door5.05144 in.lbf
Luggage compertment outside garnish x Luggage compertment door4.94943 in.lbf
BACK DOOR (LIFTBACK MODEL)
Back door femaie stopper x Door panel5.55649 in.lbf
Back door hinge assy x Body19.520014
Back door hinge assy x Door panel19.520014
Back door lock assy x Door panel8.08271 in.lbf
Back door lock Striker x Body11.51208.0
Back door stay sub±assy x Body7.07162 in.lbf
Back door stay sub±assy x Door panel2222416
Center stop lamp assy x Door panel5.55649 in.lbf
BACK DOOR (WAGON MODEL)
Back door femaie stopper x Door panel5.55649 in.lbf
Back door hinge assy x Body19.520014
Back door hinge assy x Door panel19.520014
Back door lock assy x Door panel8.08271 in.lbf
Back door lock Striker x Body11.51208.0
Back door stay sub±assy x Body7.07162 in.lbf

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

7408V±01
B67892
1
4 3
2
B67891
10
9876 54321


A05
115
74±6
±
SLIDING ROOF/CONVERTIBL ESLIDING ROOF SYSTEM
A VENSIS RE PAIR MANUAL (RM1018E)
INSPECTION
1. INSPEC T SLIDING ROOF MO TOR SWITCH ASSY
(a ) Remove the sliding roof motor switch
( See pages 76±36 , 76±45 and 76±54 ).
(b ) Check the resistance between the terminals when oper-
ating the switch.
Standard:
T erminal s No.Switch OperationSpecified Condition
1 ± 2TI LT UP is pressedBelow 1

2 ± 3SLIDE OPEN is pressedBelow 1

1, 3 ± 2OFF10 k
or higher
If the result is not as specified, replace the switch ass y.
2 . INSPECT SLIDING ROOF MO TOR ASSY
(a ) Disconnect the sliding roof motor connector
( See pages 76±36 , 76±45 and 76±54 ).
(b) Check the resistance and voltage between the terminals of the wire harness side connector.
Standard:
Terminals No.ConditionSpecified Condition
5  Body groundConstantBelow 1

3 ± 5Ignition switch ON10 to 14 V
10 ± 5Constant10 to 14 V
6 ± 5TILT UP is pressedBelow 1

1 ± 5SLIDE OPEN is pressedBelow 1

8 ± 5Ignition switch OFF

ON, Engine idle speedPulse generation *
Reference (*): Using an oscilloscope
ItemContents
Tool Setting10 V/DIV., 20 ms/DV.
Vehicle ConditionEngine idle speed
If the result is not as specified, there may be a malfunction on
the wire harness side.

190NV±01
19±14
± STARTING & CHARGINGCHARGING SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CHARGING SYSTEM (1AZ±FE)
PRECAUTION
1. Check that the battery cables are connected to the correct terminals.
2. Disconnect the battery cables when the battery is given a quick charge.
3. Do not perform tests with a high voltage insulation resistance tester.
4. Never disconnect the battery while the engine is running.
5. Check that the charging cable is tightened on terminal B of the generator and the fuse box.

190NW±01
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow
B00543
± STARTING & CHARGINGCHARGING SYSTEM (1AZ±FE)
19±15
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.
4. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.