2003 TOYOTA AVENSIS oil temperature

100G9±02
321
45
±20
020 40 60
80100
0.1
0.2 0.3 0.5 1 2
35
10
20 30
TEMPERATURE
C(
F)
RESISTANCE k

(±4) (32) (80) (140)(104) (212)
(176)
Air
E2THAVG
E2G +B
A50378
12
Valve
A50377
A59778
M±
M+
±
ENGINE CONTROL SYSTEM SFI SYSTEM (1AZ±FSE)
10±39
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Output voltage inspection.
(1) Apply battery voltage across terminals 1 (+B) and 2(E2G).
(2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (±) tester
probe to terminal 2 (E2G).
(3) Blow air into the MAF meter, and check that the volt- age fluctuates.
(b) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween terminals 4 (THA) and 5 (E2).
Resistance:
TerminalsResistanceTemperature
THA ± E213.6 to 18.4 k
±20
C (±4
F)
THA ± E22.21 to 2.69 k
20
C (68
F)
THA ± E20.49 to 0.67 k
60
C (140
F)
2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance: 6.9 to 7.9
at 20
C (68
F)
(b) Movement inspection. (1) Connect the positive (+) lead from the battery to ter-minal 1 and negative (±) lead to terminal 2, and
check the movement of the valve.
NOTICE:
Confirm the valve does not adhere.
HINT:
Bad returning of the valve by entrance of foreign objects causes
subtle pressure leak to the advanced direction. Then, DTC can
be detected.
3. INSPECT THROTTLE BODY ASSY
(a) Using an ohmmeter, measure the resistance between the terminals.
Resistance:
Terminal No.Resistance
2 (M+) ± 1 (M±)0.3 to 100
at 20
C (68
F)
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A53763
E2PSW
10±38
±
ENGINE CONTROL SYSTEMSFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
2.INSPECT POWER STEERING OIL PRESSURE SEN- SOR
(a)Using a voltmeter, measure the voltage between termi-
nals PSW and E2.
Voltage:
ConditionVoltage (V)
Not spin the steering wheel at engine idling9 to 14
Spin the steering wheel at engine idling0 to 3
3.INSPECT THROTTLE BODY
(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±39), 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±39), wiring
and ECM.
If you have no hand±held tester, measure voltage between terminals (VTA1 ± E2, VTA2 ± E2) of the ECM
connector (See page 05±318).
(c) Inspect the air assist system.
(1) Start the engine and check that the CHK ENG does not light up.
(2) Allow the engine to warm up to normal operating temperature.
(3) Turn the A/C compressor ON to OFF, and check the idle speed.
Idle speed (Transmission in neutral): 700
50 rpm
NOTICE:
Perform inspection under condition without electrical load.
(d) After checking the above (b) to (d), perform the driving test and check that there is no sense of incon-
gruity.
4. INSPECT ACCELERATOR PEDAL POSITION SENSOR
(a) Connect the hand±held tester to the DLC3.
(b) Turn the ignition switch ON.
(c) Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value.
Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depress: 2.6 to 4.5 V
(d) Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value. Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depress: 3.4 to 5.3 V
If you have no hand±held tester, measure voltage between terminals (VPA ± EPA, VPA2 ± EPA2) of the ECM
connector (See page 05±318).
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100EY±02
A60548
AirE2THAVG
E2G +B
30
20
10
5
3
2
1
0.5
0.3
0.2
0.1
RESISTANCE k

±20 0 20 40 60 80 100 54321
(±4)(32)(68)(104)(140)(176)(212) TEMPERATURE
C(
F)
A60549
1 2
Valve
±
ENGINE CONTROL SYSTEM SFI SYSTEM (1ZZ±FE/3ZZ±FE)
10±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Output voltage inspection.
(1) Apply battery voltage across terminals 1 (+B) and 2(E2G).
(2) Connect the positive (+) tester probe to terminal 3 (VG), and negative (±) tester probe to terminal 2
(E2G).
(3) Blow air into the MAF meter, and check that the volt- age output fluctuates.
(b) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween terminals 4 (THA) and 5 (E2).
Resistance:
TerminalsResistanceTemperature
THA ± E213.6 to 18.4 k
±20
C (±4
F)
THA ± E22.21 to 2.69 k
20
C (68
F)
THA ± E20.49 to 0.67 k
60
C (140
F)
2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Resistance inspection. (1) Using an ohmmeter, measure the resistance be-
tween terminals.
Resistance: 6.9 to 7.9
at 20
C (68
F)
(b) Movement inspection. (1) Connect the positive (+) lead from the battery to ter-minal 1 and negative (±) lead to terminal 2, and
check the movement of the valve.
NOTICE:
Confirm the valve does not adhere.
HINT:
Bad returning of the valve by catching of foreign objects causes
subtle pressure leak to the advanced direction. DTC can be de-
tected.
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A62779SST
A79153
A62166
SST
11±72
±
FUELINJECTION OR SUPPLY PUMP ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(b)Using SST, remove the injection pump drive pulley. SST09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±05021)
36.REMOVE INJECTION OR SUPPLY PUMP ASSY
(a)Remove the 2 nuts and the injection pump.
37.INSTALL INJECTION OR SUPPLY PUMP ASSY Torque: 21 N
m (210 kgf
cm, 15 ft
lbf)
38.INSTALL INJECTION PUMP DRIVE PULLEY
(a)Using SST, install the pulley nut.SST09960±10010 (09962±01000, 09963±01000)
Torque: 64 N
m (650 kgf
cm, 47 ft
lbf)
39.INSTALL WATER INLET(See page 16±50)
40.INSTALL OIL LEVEL GAGE GUIDE(See page 17±22)
41. INSTALL INTAKE MANIFOLD INSULATOR NO.1 Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
42. INSTALL INJECTION PIPE SUB±ASSY NO.1
NOTICE:
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.
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A62592
SST
A09663
:Seal Packing
±
ENGINE MECHANICALCAMSHAFT(1CD±FTV)
14±323
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install the oil seal retainer with the 4 bolts. Tighten the 4
bolts uniformly in several steps.
Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
46.INSTALL CAMSHAFT TIMING PULLEY
(a)Install the pulley set key to the groove of the camshaft.
(b)Align the keyway of the timing pulley with the key located on the camshaft, slide the pulley into place.
(c)Using SST, install the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
47.INSTALL CAMSHAFT POSITION SENSOR (See page 10±63)
48.INSTALL INJECTOR ASSY (See page 11±60)
49.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST09992±00242
50.INSTALL CYLINDER HEAD COVER SUB±ASSY
(a)Remove any old packing (FIPG) material.
(b)Apply seal packing to the cylinder head.Seal packing: Part No. 08826±00080 or equivalent
(c)Install the gasket to the cylinder head cover.
(d)Install the cylinder head cover with the 10 bolts.
Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
51.INSTALL NOZZLE HOLDER SEAL
(a)Install 4 new nozzle holder seals.
52.INSTALL VACUUM PUMP ASSY Torque: 21 N
m (214 kgf
cm,15 ft
lbf)
53.INSTALL INJECTION PIPE SUB±ASSY NO.1(See page 11±60)
NOTICE:
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.
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A09663
:Seal Packing
14±338
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
76.INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14±318)
77.INSTALL CAMSHAFT TIMING PULLEY (See page 14±318) SST 09960±10010 (09962±01000, 09963±01000)
78.INSTALL CAMSHAFT POSITION SENSOR (See page 10±64)
79.INSTALL INJECTOR ASSY(See page 11±60)
80.INSTALL NOZZLE LEAKAGE PIPE ASSY(See page 11±60) SST 09992±00242
81. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head.Seal packing: Part No. 08826±00080 or equivalent
(c) Install the gasket to the head cover.
(d) Install the cylinder head cover with the 10 bolts. Torque: 13 N
m (135 kgf
cm, 9.7 ft
lbf)
82. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
83.INSTALL VACUUM PUMP ASSY (See page 14±318) 84. INSTALL INJECTION PIPE SUB±ASSY NO.1(See page 11±60)
NOTICE:
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.
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A79148
SST
A79149
SST
14±340
±
ENGINE MECHANICALCYLINDER HEAD GASKET(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
88.INSTALL FUEL INLET PIPE SUB±ASSY
NOTICE:

In case of having the cylinder head gasket replaced,
must replace 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.
SST09023±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 pump side.
SST09023±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.
89.INSTALL TURBOCHARGER SUB±ASSY (See page 13±11)
90.INSTALL TURBO OIL INLET PIPE SUB±ASSY (See page 13±11)
91.INSTALL TURBOCHARGER STAY (See page 13±11)
92.INSTALL EXHAUST MANIFOLD CONVERTER SUB±ASSY (See page 13±11)
93.INSTALL MANIFOLD STAY NO.2 (See page 13±11)
94.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13±11)
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A79295
N´m (kgf´cm, ft´lbf): Specified torque

Non±reusable part
5.0 (50, 43 in.
lbf)

O±ring

Gasket

Gasket

Gasket


Gasket

O±ring
15 (153, 11)
20 (204, 15)
9.0 (92, 80 in.
lbf)
9.0 (92, 80 in.
lbf)
Fuel Delivery Pipe
w/ Injector
Oil Control Valve Knock Control Sensor Spacer
Water By±pass Pipe No. 1 Oil Level Gauge
Sub±assy
Oil Level Gauge Guide
Water Inlet
9.0 (92, 79 in.
lbf)Engine Oil Pressure Switch Assy
Water Temperature Sensor
Thermostat
9.0 (92, 80 in.
lbf)
19 (194, 14)
19 (194, 14)
20 (204, 15)
14±120
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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