2002 TOYOTA AVENSIS INTAKE AIR

160ME±01
A79148
SST
16±46
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
WATER PUMP ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE ENGINE ROOM COVER SIDE
3.DRAIN ENGINE COOLANT(See page 16±44)
4.REMOVE FRONT WHEEL RH
5.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
6.REMOVE ENGINE UNDER COVER RH
7.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
8.REMOVE INJECTOR DRIVER (See page 14±286)
9.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
10.REMOVE GENERATOR V BELT (See page 14±269)
11.SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
12.SEPARATE ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
13.REMOVE CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021, 09950±50013 (0995\
1±05010, 09952±05010, 09953±05020, 09954±05031)
14. REMOVE IDLER PULLEY SUB±ASSY
(a) Remove the bolt, the washer and the pulley.
15.REMOVE TIMING BELT NO.2 COVER(See page 14±307)
16.REMOVE TIMING BELT NO.1 COVER(See page 14±307)
17. REMOVE TIMING BELT GUIDE
18.REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
19.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307)
20.REMOVE TIMING CHAIN COVER PLATE(See page 14±307)
21.REMOVE TIMING BELT(See page 14±307)
22. REMOVE FUEL INLET PIPE SUB±ASSY(See page 11±69)
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Remove the wire bracket and slide the engine wire.
(b) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023±12700
(c) Using SST, remove the fuel inlet pipe from the injection pump.
SST 09023±12700
23.REMOVE INTAKE MANIFOLD INSULATOR NO.1(See page 11±69)
24. REMOVE OIL LEVEL GAGE SUB±ASSY
25.REMOVE OIL LEVEL GAGE GUIDE(See page 17±22)
26.REMOVE WATER INLET (See page 16±50)
27.DISCONNECT INJECTION PUMP TO FUEL PIPE FUEL HOSE(See page 11±69)
28.DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE(See page 11±69)

A79148
SST
A79149
SST
16±48
±
COOLING WATER PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
39.INSTALL INTAKE MANIFOLD INSULATOR NO.1(See page 11±69) 40. INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the water pump replaced, must re-
place fuel inlet pipe, too.

When assembling the pipe, perform the operation
with the engine cold under room temperature.
(a) Temporarily install the new fuel inlet pipe.
(b) Using SST, tighten the nut of the fuel inlet pipe to the com-
mon rail side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe to the injec- tion pump side.
SST 09023±12700
Torque:
42 N
m (428 kgf
cm, 31 ft
lbf) for a used pipe using SST
46 N
m (469 kgf
cm, 34 ft
lbf) for a used pipe not using
SST
31 N
m (316 kgf
cm, 23 ft
lbf) for a new pipe using SST
34 N
m (347 kgf
cm, 25 ft
lbf) for a new pipe not using
SST
HINT:

Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)

Check if the used pipe has deflection or is installed prop-
erly after inlet pipe is reassembled. If there is deflection
or if it can not be installed properly, replace the used pipe
with a new pipe.

1209I±02
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
12±17
AVENSIS REPAIR MANUAL (RM1018E)
EGR SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
HINT:
In a malfunction where the EGR system is always on, black smoke or white smoke may be emitted from the
exhaust pipe. If this occurs, inspect the EGR system as well.
1. INSPECT SEATING OF EGR VALVE
(a) Start the engine and check that it starts and runs at idle.
2. INSPECT HOT ENGINE CONDITION (WHEN USING HAND±HELD TESTER)
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Refer to the hand±held tester operator's manual for further details.
(d) Warm up the engine, the coolant temperature should be above 75
C (109
F) and bellow 90
C
(194
F).
(e) Check that the AFM reading is 5
ega
8 g/s with the engine idling.
(f) Operate the EGR valve with a hand±held tester. Regulate the valve opening angle to 0, and check that
the AFM reading is 11
ega
17 g/s..
If the AFM reading is out of range in either (e) or (f), replace the EGR valve.
If the AFM is out of range in both (e) and (f), replace the air flow meter (air cleaner) and check the EGR valve
operation again.
3. INSPECT HOT ENGINE CONDITION (WHEN NOT USING HAND±HELD TESTER)
(a) Install the vacuum gauge.
(1) Using a 3±way connector, connect a vacuum gauge to the hose between the intake manifold and
the turbo pressure sensor.
(b) Warm up the engine, the coolant temperature should be above 75
C (109
F) and bellow 90
C
(194
F).
(c) Check that the vacuum gauge indicates about more than 2.5 kPa (19 mmHg 0.7 in Hg).
(d) Stop the engine (IG OFF), remove the EGR valve connector, restart the engine, and check that load
under idling is less than 2.5 kPa (19 mmHg 0.7 in Hg).
If the load pressure exceeds the above value, replace the EGR valve.

1209F±02
A62250
Port A
Port BPort C
A60562
Cylinder Head Side
A60563
Intake Manifold Side
Gasket
B11870
12±8
± EMISSION CONTROLEMISSION CONTROL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT CHARCOAL CANISTER ASSY
(a) Inspect charcoal canister operation.
(1) Check the charcoal canister operation according to
the table below.
SST 09992±00242
Inspection:
Checking methodResult
Close ports B and C, then apply vacuum
to port ANo leaks
Close port C, then apply vacuum to port
AAir flows from port B
Close port C, then blow air into port AAir flows from port B
Blow air into port AAir flows from ports B and C
2. INSPECT VENTILATION VALVE SUB±ASSY
(a) Install clean hose to the PCV valve.
(b) Inspect the PCV valve operation.
(1) Blow air into the cylinder head side, and check that
air passes through easily.
CAUTION:
Do not suck air through the valve. If contains petroleum
substances and is harmful.
(2) Blow air into the intake manifold side, and check
that air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
(c) Remove clean hose from the PCV valve.
3. INSPECT FUEL TANK CAP ASSY
(a) Visually check if the cap or gasket is deformed or dam-
aged.
If necessary, repair or replace the cap.

1209H±02
A62250
Port A
Port BPort C
A60562
Cylinder Head Side
A60563
Intake Manifold Side
Gasket
B11870
± EMISSION CONTROLEMISSION CONTROL SYSTEM (1AZ±FSE)
12±13
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT CHARCOAL CANISTER ASSY
(a) Inspect charcoal canister operation.
(1) Check the charcoal canister operation according to
the table below.
SST 09992±00242
Checking methodResult
Close ports B and C, then apply vacuum
to port ANo leaks
Close port C, then apply vacuum to port
AAir flows from port B
Close port C, then blow air into port AAir flows from port B
Blow air into port AAir flows from ports B and C
2. INSPECT VENTILATION VALVE SUB±ASSY
(a) Install clean hose to the PCV valve.
(b) Inspect the PCV valve operation.
(1) Blow air into the cylinder head side, and check that
air passes through easily.
CAUTION:
Do not suck air through the valve. If contains petroleum
substances and is harmful.
(2) Blow air into the intake manifold side, and check
that air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
(c) Remove clean hose from the PCV valve.
3. INSPECT FUEL TANK CAP ASSY
(a) Visually check if the cap or gasket is deformed or dam-
aged.
If necessary, repair or replace the cap.

A77118
Air E
F
Battery
A60562
Cylinder Head Side
A60563
Intake Manifold Side
A64543
+B
Bank 1 Sensor 1:
HT1A
E1
A77126
HT +B
Bank 1 Sensor 2:
E1 12±4
± EMISSION CONTROLEMISSION CONTROL SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(2) Apply battery voltage across the terminals.
(3) Check that air flows from port E to port F.
If operation is not as specified, replace the VSV.
3. INSPECT VENTILATION VALVE SUB±ASSY
(a) Blow air into the cylinder head side, and check that air
passes through easily.
CAUTION:
Do not suck air through the valve. If contains petroleum
substances and is harmful.
(b) Blow air into the intake manifold side, and check that air
passes through with difficulty.
HINT:
If operation is not as specified, replace the PCV valve.
4. IINSPECT HEATED OXYGEN SENSOR
(a) Bank 1 Sensor 1:
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Terminal No.Resistance
1 (HT1A) ± 2 (+B)5 to 10
at 20
C (68
F)
1 (HT1A) ± 4 (E1)No Continuity
If the resistance is not as specified, replace the sensor.
(b) Bank 1 Sensor 2:
(1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance:
Terminal No.Resistance
1 (HT) ± 2 (+B)11 to 16
at 20
C (68
F)
1 (HT) ± 4 (E1)No Continuity
If the resistance is not as specified, replace the sensor.

100F0±02
321 4 5
±20
020 40 60
80100 0.1 0.2 0.3 0.51 235 1020 30
TEMPERATURE
C(
F)
RESISTANCE k

(±4) (32) (80) (140)(104) (212)(176)
A56275
VG
E2G
THA +B E2 Air
A31135
10±56
± ENGINE CONTROL SYSTEMECD SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Output voltage inspection.
(1) Apply battery voltage across terminals 3 (+B) and 4
(E2G)
(2) Using a voltmeter, connect the positive (+) tester
probe to terminal VG, and negative (±) tester probe
to terminal E2G.
(3) Blow air into the air flow meter, and check that the
voltage fluctuates.
(b) Resistance inspection.
(1) Using an ohmmeter, measure the resistance be-
tween terminals 2 (THA) and 1 (E2).
Resistance:
±20
C (±4
F) 12.5 to 16.9 k

20
C (68
F) 2.19 to 2.67 k

60
C (140
F) 0.50 to 0.68 k

2. INSPECT INTAKE SHUTTER ASSY
(a) Resistance inspection (Throttle control motor)
(1) Using an ohmmeter, measure the resistance be-
tween terminals.
Resistance:
TerminalsTemperatureResistance
2 ± 1, 3at 20
C (68
F)18 to 22 k

5 ± 4, 6at 20
C (68
F)18 to 22 k

100EZ±02
A75903
Air
A53763
VG
EVG
10±54
±
ENGINE CONTROL SYSTEM ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ECD SYSTEM(1CD±FTV)
ON±VEHICLE INSPECTION
1.INSPECTMASS AIR FLOW METER
(a)If you have hand±held tester: Inspect for operation
(1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON.
(3)Blow air into the MAF meter, and check that the airflow fluctuates (MAF ) of the CURRENT DATA
shown the standard value.
If operation is not as specified, check the MAF meter (See page
10±56), wiring and ECM.
(b)If you have no hand±held tester: Inspect for operation
(1)Turn the ignition switch ON.
(2)Connect the positive tester probe of the voltmeterto the terminal VG of the ECM. and the negative tes-
ter probe of the voltmeter to the terminal EVG of the
ECM.
(3)Blow air into the MAF meter, and check that the volt- age fluctuates.
If operation is not as specified, check the MAF meter (See page
10±56), wiring and ECM.
2.INSPECT INTAKE SHUTTER
(a)Inspect the throttle control motor for operating sound. (1)Turn the ignition switch ON.
(2)When turning the accelerator pedal position sensor lever, check the running sound of the motor.
Also, check that there is no friction sound.
If operation is not as specified, check the throttle control motor (See page 10±56), wiring and ECM.
(b)Inspect the throttle position sensor. (1)Connect the hand±held tester to the DLC3.
(2)Turn the ignition switch ON.
(3)When turning the accelerator pedal position sensor lever to the full±\
open position, check thatthe throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the
standard value.
Standard throttle valve opening percentage:
60 % or more
If operation is not as specified, check that the accelerator pedal positio\
n sensor (See page 10±56), wiring
and ECM.
If you have no hand±held tester, measure voltage between terminals (LU+A ± LU±A, LU+B ± LU±\
B) of the
ECM connector (See page 05±549).