2003 TOYOTA AVENSIS check engine

A62181
PlungerTurn
Push
A10085
A62182
Seal Packing
14±26
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(4) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released from the knock pin and the plunger springs out.
66. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Install the gasket to the cylinder head cover.
(b) Remove any old packing (FIPG) material.
(c) Apply seal packing to 2 locations as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not put into engine oil 2 hours after installing.
(d) Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts
Uniformly tighten the bolts and nuts, in the several
passes.
Torque:
w/o washer 11 N
m (112 kgf
cm, 8 ft
lbf)
w/ washer 9.0 N
m (92 kgf
cm, 80 in
lbf)
67. INSTALL SPARK PLUG
(a) Using a spark lug wrench, install the 4 spark plugs. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
http://vnx.su

010BJ±01
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TERMS (1ZZ±FE/3ZZ±FE)
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector
http://vnx.su

010BH±01
A54988
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part Camshaft Timing Tube Assy
Camshaft Drive Gear
Seal Washer
Camshaft Setting Oil Seal No. 2 Camshaft,
No. 4 Camshaft Sub±assy
Wave Washer Camshaft Driven Main Gear
Snap Ring Camshaft Timing Gear
Bolt Washer
Screw Plug
78 (790, 58)
15 (150, 11)
7.5 (80, 66 in.´lbf)
Camshaft Sub Gear
Camshaft,
No. 3 Camshaft Sub±assy
OVERHAUL
±
INTRODUCTION HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
01±1
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main pro\
cesses:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Che\
cking, Adjusting
3. Final Inspection
(c) This manual explains ºRemoving and Installing, Replacing, Disassembling, Installing and Checking, Adjustingº, but ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual, howev\
er these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to\
be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) \
may be required, depending on the repairing condition. Be sure to use SST and SSM when they are requi\
red and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title when necessary.
(b) Illustrations of the parts catalog are placed as the ºdisassembled parts drawingº\
so that it enables you to understand the fitting condition of the components.
(c) Non±reusable parts, grease applied parts, precoated parts and tightening torque are \
specified in the components drawing.
Example:
http://vnx.su

010BK±01
01±12
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
http://vnx.su

±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±13
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
http://vnx.su

L1L2
D02612
L2
L1
D01201
L2
L1
D01202
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
01±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
NOTICE:
Do the torque checking with the lower limit value of the torque toleranc\
e.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets: When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always\
use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:(1) In case of tightening by extending the entire lengthof the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that\
vaporized fuel fills those places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,and do not spray much water so as to prevent slipping.
http://vnx.su

D01563
D25081
Flat Spring Clamp
Clamp Track
01±6
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(3) Never use any electric equipment like an electric motor or a working light as they may cause spark or high temperature.
(4) Never use an iron hammer as it may cause spark.
(5) Dispose the shop lag separately from any fuel deposit.
11. REMOVAL AND INSTALLATION OF ENGINE INTAKEPARTS
(a) If any metal tip is mixed in the inlet pass, that may give a bad effect to the engine and turbo charger.
(b) When removing and installing of the inlet system parts, close the opening of the removed inlet system parts and
the engine with a clean shop lag or gum tape.
(c) When installing the inlet system parts, check that there is no mixing of a metal tip.
12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of inserting portion and the clamp position to restore it surely.
(b) Change a deformed or dented into a new one.
(c) In case of reusing the hose, install the clamp on the hose where it has a clamp track.
(d) For a flat spring type clamp, make it adjust by adding force to the arrow mark direction after the installation.
http://vnx.su

1700D±03
B00307
Oil Jet
A32175
A32176
A32178
17±2
±
LUBRICATION OIL PUMP ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE OIL PUMP DRIVE AND DRIVEN ROTORS
(a) Remove the 3 screws and oil pump cover.
(b) Remove the oil pump drive and driven rotors from the oil pump.
2. REMOVE VALVE, OIL PUMP RELIEF
(a) Remove the plug, spring and valve from the oil pump. 3. INSPECT OIL JET
(a) Check the oil jet for damage or clogging.
4. INSPECT OIL PUMP RELIEF VALVE
(a) Coat the oil pump relief valve with engine oil, and checkthat it falls smoothly into the valve hole by its own weight.
5. INSPECT ROTOR TIP CLEARANCE
(a) Using a feeler gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance:
0.040 ± 0.160 mm (0.0016 ± 0.0063 in.)
Maximum tip clearance: 0.160 mm (0.0063 in.)
6. INSPECT ROTOR SIDE CLEARANCE
(a) Using a feeler gauge and precision straight edge, mea- sure the clearance between the 2 rotors and precision
straight edge.
Standard side clearance:
0.025 ± 0.071 mm (0.0010 ± 0.0028 in.)
Maximum side clearance: 0.071 mm (0.0028 in.)
http://vnx.su