2002 TOYOTA AVENSIS check engine light

I30899
Fuel Sender Gauge: 71±4
± INSTRUMENT PANEL/METERCOMBINATION METER
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT TACHOMETER
(a) Check the operation
(1) Connect a tune±up test tachometer, and start the engine.
NOTICE:

Reversing the connection of the tachometer will damage the transistors and the insides of the
diodes .

When removing or installing the tachometer, be careful not to drop or subject it to heavy
shocks.
(2) Compare the result of the test with standard indication.
DC 13.5 V, 25 C at (77 F)
Standard indication (r/min)Acceptable range (r/min)
Data in ( ) are for reference
700630 ± 770
1,000(900 ± 1100)
2,000(1850 ± 2150)
3,0002800 ± 3200
4,000(3800 ± 4200)
5,0004800 ± 5200
6,000(5750 ± 6250)
7,0006700 ± 7300
4. INSPECT FUEL RECEIVER GAUGE
(a) Inspect the circuit.
(1) Disconnect the connector from the sender gauge.
(2) Turn the ignition switch to ON, then check the posi-
tion of the receiver gauge needle.
Needle position: EMPTY
(3) Connect the terminal 2 and 3 on the wire harness
side connector of fuel sender gauge.
(4) Turn the ignition switch to ON, then check the posi-
tion of the receiver gauge needle.
Needle position: FULL
5. INSPECT FUEL LEVEL WARNING
(a) Inspect the circuit.
(1) Disconnect the connector from the sender gauge.
(2) Turn the ignition switch to ON, check the fuel level needle indicates EMPTY and fuel level warn-
ing light comes on.
6. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE WARNING LIGHT
(a) Inspect the circuit.
(1) Disconnect the connector from the sender gauge.
(2) Turn the ignition switch to ON, check the position of the water temperature receiver gauge
needle.
Needle position: COOL
(3) Ground the terminal 2 on the wire harness side, then check the position of the water temperature
receiver gauge needle.
Needle position: HOT

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.

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.

D01556
WRONG
D01563
01±16
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(±) terminal cable is disconnected. If necessary, be
sure to initialize the system.
(b) HANDLING OF ELECTRONIC 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 rendered inoperative by
static electricity).
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission±re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation and without anything that could cause combustion
around you such as a welder, grinder, drill, electric motor or stove.
(2) Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel
will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operations.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray much water so as to prevent slipping.
(3) Never use any electric equipment like an electric motor or a working light, as they may create
sparks or a high temperature.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of shop rags containing fuel deposits separately.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, this may give a
bad effect to the engine and turbocharger.
(b) When removing and installing the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean waste cloth or gum tape.
(c) When installing the inlet system parts, check that there is
no mixing of a metal tip.

650SY±01
I35230
±
LIGHTING FOG LAMP ASSY LH
65±23
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1.PUT VEHICLE THESE CONDITIONS
(a)Tire inflation pressure is within the specified value. (See page 28±1)
(b) Start the engine.
2. ADJUST FOG LIGHT AIM
(a) The fog light aim can be adjusted by turning the aimingscrew in the vertical direction.
HINT:
The optical aim moves upward when turning the screwdriver
clockwise and moves downward when turning the screwdriver
center clockwise.
3. CHECK FOG LIGHT AIM

I35248
V LH Line
V RH Line
V Line90
3 m (9.84 ft)
I37308
Low Beam:V LH Line
V RH Line
30mm
(1.18 in.)84 mm
(3.3 in.)
H Line6mm
(0.23 in.)
I37102
High Beam:V LH Line
V RH Line
H Line
I35802Adjusting Bolt A
Adjusting Bolt B
65±20
± LIGHTINGHEADLAMP UNIT LH
AVENSIS REPAIR MANUAL (RM1018E)
(c) Check the headlight aiming.
(1) Align the paper with the center of the vehicle.

Make a distance of 3 m ( 9.84 ft) between the head-
lights and the paper, and put the paper against a
wall with the H line being at the same height as the
center mark.

Align the center of the vehicle with the V line on the
paper, and ensure that the paper is at a 90 angle
in accordance to the V line.
(2) Start the engine.
(3) Turn on the headlights and check that the aim is with
in the specified valves shown in the illustration.
NOTICE:

When covering the headlights, finish it within 3 mi-
nuites.

The headlight lens is made of synthetic resin, so it is
easily.
HINT:
When checking the aiming of the High±beam, shut off the Low±
beam or disconnect the Low±beam headlight connector.
(d) Adjust the aim in the vertical direction:
Using a screwdriver, adjust the headlight aim within the
specified range by turning the aiming screw A.
NOTICE:

Adjust the headlight aim by turning the screw in the
tightening direction.

When the screw is tightened excessively, loosen it
once and re±tighten it to adjust the headlight aim.
HINT:
The optical axis aim moves downward when turning the screw-
driver clockwise, and it moves upward when turning the screw-
driver counterclockwise.
(e) Adjust the aim in the horizontal direction:
Using a screwdriver, adjust the headlight aim within the
specified range by turning the aiming screw B.
NOTICE:

Adjust the headlight aim by turning the screw in the
tightening direction.

When the screw is tightened excessively, loosen it
once and re±tighten it to adjust the headlight aim.

± LIGHTINGLIGHTING SYSTEM
65±7
AVENSIS REPAIR MANUAL (RM1018E)
(b) Connect the connector to the headlamp leveling ECU
assy, then turn the ignition switch ON and light control
switch into HEAD position. Inspect the wire harness side
connector from the back side as shown in the chart.
Standard:
Tester connectionConditionSpecified condition
2 ± body groundAlways5 V
3 ± body ground3 secs. after vehicle height change for 10 secs.1.0 to 13 V
4 ± body ground3 secs. after vehicle height change for 10 secs.1.0 to 13 V
5 ± body groundAlways0 to 5 V
6 ± body groundAlways0 to 5 V
10 ± body groundHeadlamp Switch is OFF
ON10 to 14 V
Below 1 V
11 ± body groundBeam level warning light OFF
ON10 to 14 V
Below 1 V
12 ± body groundTurn the vehicle wheelPuls generation
13 ± body groundAlways10 to 14 V
14 ± body groundAlways10 to 14 V
15 ± body groundAlways5 V
20 ± body groundAlwaysBelow 1 V
21 ± body groundAlwaysBelow 1 V
22 ± body groundAlwaysBelow 1 V
23 ± body groundAlwaysBelow 1 V
4. HEADLAMP AUTO LEVERING OPERATION CHECK
(a) Check that the initialization (determination of the initial position) for the leveling motor is performed at
the engine±start.
(b) Check that the warning indicator in the combination meter assy illuminates for approximately 3 se-
conds at the engine±start and then goes off.
(c) Check that the reflector works when:
Keeping the rear of the vehicle up or down while the engine is running with the vehicle stopped and
the headlamp dimmer switch in the HEAD position.
NOTICE:
Make sure to change the vehicle's height slowly.
5. FAIL±SAFE FUNCTION
(a) Headlamp Leveling Control ECU
HINT:
The Headlamp Leveling Control ECU performs the fail±safe when detecting following troubles. At this the
warning indicator light on the combination meter lights up.
Trouble AreaConditionHeadlight levering motor
1. Height control sensor
Signal level error

Out of voltageStop leveling operation
2. Headlamp leveling control ECU
Watchdock detection

High voltageStop leveling operation