2003 TOYOTA AVENSIS check engine

A79147
SST
30 cm
(11.81 in.)
11±64
±
FUELINJECTOR ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
20.INSTALL NOZZLE HOLDER SEAL
(a)Install new 4 nozzle holder seals.
21.INSTALL TIMING BELT NO.2 COVER(See page 14±307) 22. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:

In case of having the injectors replaced, must replace
the injection pipes, too.

When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and
vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail.
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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor.
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 injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
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±
FUELINJECTOR ASSY(1CD±FTV)
11±65
AVENSIS REPAIR MANUAL (RM1018E)
23.INSTALL INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
24.INSTALL INJECTION PIPE SUB±ASSY NO.3
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
25.INSTALL INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
26.INSTALL AIR TUBE NO.1 (See page 14±270)
27. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
28. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
29. INSTALL VACUUM RESERVOIR SUB±ASSY Torque: 8.3 N
m (85 kgf
cm, 74 in.
lbf)
30. CHECK FOR FUEL LEAKS
NOTICE:
Under ACTIVE TEST mode, fuel pressure increases. Take precautions to prevent fuel from spraying
on you or inside the engine compartment.
HINT:
During ACTIVE TEST mode, engine speed goes high and combustion noise bec\
omes loud.
(a) Check that there are no fuel leaks from any part of the fuel system at t\
he engine stops.
HINT:
If fuel leakage could be found on specific parts, replace them with new \
parts.
(b) While cranking or when starting the engine, check that there is no leaks from\
any part of the fuel sys-
tem.
HINT:
If fuel leakage could be found on specific parts, replace them with new pa\
rts.
(c) Disconnect the fuel hose from the common rail.
(d) While cranking the engine, check fuel leaks from the return pipe.
HINT:
If there is fuel leakage, replace the common rail.
(e) Connect the hand±held tester to the DLC3.
(f) Start the engine and push the hand±held tester main switch ON.
(g) Select the FUEL LEAK test of ACTIVE TEST mode on the hand±held tester\
.
(h) If you do not have the hand±held tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this opera\
tion several times.
(i) Check that there are no leaks from any part of the fuel system.
NOTICE:
If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in\
a minute, it is acceptable.
HINT:
If fuel leakage could be found on specific parts, replace them with new \
parts.
(j) Reconnect the fuel hose to the common rail.
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1209I±02
±
EMISSION CONTROL EGR 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 s\
moke 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 m\
eter (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 andthe 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 i\
n 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.
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1209E±02
A65749
E1OX2BOX1B
ECM
A77114
12±6
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT AIR±FUEL RATIO COMPENSATION SYS- TEM
HINT:
You can also check the system by choosing ºDATA MONITOR/
O
2 SENSOR OUTPUT VOLTAGEº on the monitor of the hand±
held tester.
(a) Connect the hand±held tester to terminals 21 (OX1B) and 7 (E1) and to terminals 29 (OX2B) and 7 (E1) of the ECM.
CAUTION:
Connect test leads from the back side of the connector with
the ECM connected.
(b) Warm up the heated oxygen sensor with the engine speed at 2,500 rpm for approximately 2 minutes.
(c) Confirm that the voltage output varies between 0V to 1V with the engine speed at 2,500 rpm.
OK:
The voltage output varies more than 8 times in 10 se-
conds.
CAUTION:

Perform the check immediately after the warming up.

If the voltage variation could not be verified, warm up
the heated oxygen sensor again.
2. INSPECT FUEL CUT OFF RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating sounds.
(c) Check that injector operating sounds stops momentarily and then resumes when \
the throttle lever is released.
3. INSPECT EVAPORATIVE EMISSION CONTROL SYS-TEM
(a) After starting the engine, disconnect the vacuum hose
shown in the illustration.
(b) Check if vacuum occurs at the VSV port when choosing ºACTIVE TESTº and ºPURGE VSVº according to the dis-
play on hand±held tester.
(c) Finish ºACTIVE TESTº, then reconnect the vacuum hose.
(d) After entering to ºECU DATA MONITORº on the hand±
held tester, choose ºPURGE VSVº to check the operation
of the purge VSV.
(e) After driving the vehicle with a warm engine, confirm that
the VSV turns from off to on.
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1209G±02
A59588
E1
OX1A OX1B
OX2B
OX2A
ECM
A77114
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FSE)
12±11
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
1. INSPECT AIR±FUEL RATIO COMPENSATION SYS-
TEM
HINT:
You can also check the system by choosing ºDATA MONITOR/
O
2 SENSOR OUTPUT VOLTAGEº on the monitor of the hand±
held tester.
(a) Connect the hand±held tester to the following each pair of the ECM terminals:
(1) Terminals 21 (OX1B) and 1 (E1)
(2) Terminals 22 (OX1A) and 1 (E1)
(3) Terminals 23 (OX2A) and 1 (E1)
(4) Terminals 29 (OX2B) and 1 (E1)
CAUTION:
Connect test leads from the back side of the connector with
the ECU connected.
(b) Warm up the heated oxygen sensor with the engine speed at 2,500 rpm for approximately 2 minutes.
(c) Confirm that the voltage output varies between 0V to 1V with the engine speed at 2,500 rpm.
OK:
The voltage output varies more than 8 times in 10 se-
conds.
CAUTION:

Perform the check immediately after the warming up.

If the voltage variation could not be verified, warm up
the heated oxygen sensor again.
2. INSPECT FUEL CUT OFF RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating sounds.
(c) Check that the injector operating sounds stops momentarily and then resumes th\
at when the throttle lever is released. 3. INSPECT EVAPORATIVE EMISSION CONTROL SYS-TEM
(a) After starting the engine, disconnect the vacuum hose
shown in the illustration.
(b) Check if vacuum occurs at the VSV port when choosing ºACTIVE TESTº and ºPURGE VSVº according to the dis-
play on hand±held tester.
(c) Finish ºACTIVE TESTº, then reconnect the vacuum hose.
(d) After entering to ºECU DATA MONITORº on the hand±
held tester, choose ºPURGE VSVº to check the operation
of the purge VSV.
(e) After driving the vehicle with a warm engine, confirm that
the VSV turns from off on to.
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1203V±03
B08075
12±16
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS
(a) Check for cracks, leak or damage.
HINT:
Separation of the engine oil dipstick, oil filler cap, PCV hose,
etc. may cause the engine to run improperly. Disconnection,
looseness or cracks in the parts of the air induction system be-
tween the throttle body and cylinder head will allow air suction
and cause the engine to run improperly.
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1209C±02
A65749
E1OX1AOX1B
ECM
A66059
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1ZZ±FE/3ZZ±FE)
12±1
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL SYSTEM (1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT AIR±FUEL RATIO COMPENSATION SYS-
TEM
HINT:
You can also check the system by choosing ºDATA MONITOR/
O
2 SENSOR OUTPUT VOLTAGEº on the monitor of the hand±
held tester.
(a) Connect the hand±held tester to the terminals 21 (OX1B) and 7 (E1) and to terminals 23 (OX1A) and 7 (E1) of the
ECM.
CAUTION:
Connect test leads from the back side of the connector with
the ECM connected.
(b) Warm up the heated oxygen sensor with the engine speed at 2,500 rpm for approximately 2 minutes.
(c) Confirm that the voltage varies output between 0V to 1V with the engine speed at 2,500 rpm.
OK:
The voltage output varies more than 8 times in 10 se-
conds.
CAUTION:

Perform the check immediately after the warming up.

If the voltage variation could not be verified, warm up
the heated oxygen sensor again.
2. INSPECT FUEL CUT OFF RPM
(a) Increase the engine speed to at least 3,500 rpm.
(b) Use a sound scope to check for injector operating sounds.
(c) Check that injector operating sounds stops momentarily and then resumes when \
the throttle lever is released.
3. INSPECT EVAPORATIVE EMISSION CONTROL SYS-TEM
(a) After starting the engine, disconnect the vacuum hose
shown in the illustration.
(b) Check if vacuum occurs at the VSV port when choosing ºACTIVE TESTº and ºPURGE VSVº according to the dis-
play on hand±held tester.
(c) Finish ºACTIVE TESTº, then reconnect the vacuum.
(d) After entering to ºECU DATA MONITORº on the hand±
held tester, choose ºPURGE VSVº to check the operation
of the purge VSV.
(e) After driving the vehicle with a warm engine, confirm that
the VSV turns from off to on.
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A62836
1ZZ±FE3ZZ±FE
12±2
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
4. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS
(a) Check for cracks, leaks or damage.
HINT:
Separation of the engine oil dipstick, oil filler cap, PCV hose,
etc. may cause the engine to run improperly. Disconnection,
looseness or cracks in the parts of the air induction system be-
tween the throttle body and cylinder head will allow air suction
and cause the engine to run improperly.
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