2003 TOYOTA AVENSIS check engine light

140D1±02
CG
TCA51075
A52004
±
ENGINE MECHANICALENGINE(1AZ±FE)
14±101
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±13)
2.INSPECT ENGINE OIL (See page 17±6)
3. INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20 C (68F)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±9)
6. INSPECT V±RIBBED BELT
7. INSPECT IGNITION TIMING
(a) Warm up engine.
(b) When using hand±held tester:(1) Connect the hand±held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12  BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF.
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.
http://vnx.su

TA C
A52006
A13304
14±102
±
ENGINE MECHANICAL ENGINE (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 15  BTDC
(7) Confirm that ignition timing to go advanced angle side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester:
(1) Connect the hand±held tester to the DLC3.
Idle speed: 650 to 750 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester.
(1) Using SST, connect the tachometer test prove toterminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 650 to 750 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
(e) Inspect cylinder compression pressure. SST 09992±00500
(1) Insert a compression gauge into the spark plughole.
(2) Fully open the throttle.
http://vnx.su

141CP±01
CG
TCA51075
A79034
±
ENGINE MECHANICALENGINE(1AZ±FSE)
14±181
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1AZ±FSE)
INSPECTION
1.INSPECT COOLANT (See page 16±25)
2.INSPECT ENGINE OIL(See page 17±13)
3.INSPECT BATTERY
Standard specific gravity: 1.25 to 1.29 at 20C (68F)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±14)
6.INSPECT V±RIBBED BELT
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12 BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect terminals 13 (TC) and 4 (CG)of DLC3.
SST 09843±18040, 09843±18020
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the cylinder head cover No.2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
(4) Inspect ignition timing at idle.
Ignition timing: 8 to 12  BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed. (5) Disconnect terminals 13 (TC) and 4 (CG) of DLC3.
http://vnx.su

TA C
A52006
14±182
±
ENGINE MECHANICAL ENGINE (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(6) Inspect ignition timing at idle.
Ignition timing: 5 to 23  BTDC
(7) Confirm that ignition timing to go advanced angle
side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester: (1) Connect the hand±held tester to the DLC3.
Idle speed: 625 to 725 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester: (1) Using SST, connect the tachometer test prove toterminal 9 (TAC) of DLC3.
SST 09843±18040
(2) Check the idle speed.
Idle speed: 625 to 725 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coil.
(d) Remove the spark plugs.
http://vnx.su

140KR±02
A62199
TCCG
A62200
±
ENGINE MECHANICALENGINE(1ZZ±FE/3ZZ±FE)
14±1
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1ZZ±FE/3ZZ±FE)
INSPECTION
1.INSPECT COOLANT (See page 16±1)
2.INSPECT ENGINE OIL (See page 17±1)
3.INSPECT BATTERY (See page 19±5)
4.INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY
5.INSPECT SPARK PLUG (See page 18±3)
6.INSPECT FAN AND GENERATOR V BELT
HINT:
You don't need to check the belt deflection because auto tensioner is ado\
pted.
7.INSPECT IGNITION TIMING
(a)Warm up engine.
(b)When using hand±held tester:
(1)Connect the hand±held tester to the DLC3.
(2)Enter DATA LIST MODE on the hand±held tester.
Ignition timing: 8 to 12BTDC
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester: (1) Using SST, connect terminal 13 (TC) and 4 (CG) ofthe DLC3.
SST 09843±18040
NOTICE:

Make sure of the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn OFF all electrical systems before connecting the
terminals.

Operate the inspection after the cooling fan motor is
turned OFF
(2) Remove the 2 nuts, and 2 clips, and then remove the cylinder head cover.
(3) Pull out the wire harness as shown in the illustration.
(4) Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which detects the first signal.

After checking, be sure to wrap the wire harness with
tape.
http://vnx.su

TA C
A52006
A01037
14±2
±
ENGINE MECHANICAL ENGINE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Inspect ignition timing at idle.
Ignition timing: 8 to 12 BTDC
NOTICE:
When checking the ignition timing, shift the transmission
to the neutral position.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that
the engine rpm returns to the idle speed.
(6) Disconnect the terminal 13 (TC) and 4 (CG) of theDLC3.
(7) Inspect ignition timing at idle.
Ignition timing:
10 to 18 BTDC (1ZZ±FE)
3.5 to 11.5 BTDC (3ZZ±FE)
(8) Confirm that ignition timing to go advanced angle side when the engine rpm is increased.
(9) Remove the timing light.
(10) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
8. INSPECT ENGINE IDLE SPEED
(a) Warm up engine.
(b) When using hand±held tester: (1) Connect the hand±held tester to the DLC3.
HINT:
Please refer to the hand±held tester operator's manual if you
need help to select DATA LIST.
(c) When not using hand±held tester:
(1) Using SST, connect the tachometer test prove toterminal 9 (TAC) of DLC3.
SST 09843±18040
(d) Check the idle speed. Idle speed: 600 to 700 rpm
NOTICE:

Check the idle speed with the cooling fan OFF.

Switch off all accessories and air conditioning before
connecting the test prove to the terminal.
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Remove the ignition coil.
(c) Remove the spark plugs.
(d) Inspect cylinder compression pressure. SST 09992±00500
(1) Insert a compression gauge into the spark plughole.
(2) Fully open the throttle.
http://vnx.su

A01163
A62798
Paint Mark
90

Front
A01160
A62799
Mark
1, 2 or 3
A01166
14±40
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(g) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.
(h) Using SST, tighten the bolts in several passes by the spe-
cified torque.
SST 09205±16010
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(i) Mark the front of the connecting cap bolts with paint.
(j) Retighten the cap bolts by 90  as shown in the illustration.
(k) Check that the crankshaft turns smoothly.
(l) Remove the 2 bolts, connecting rod cap and lower bear- ing.
(m) Measure the Plastigage at its widest point. Standard oil clearance:
0.028 ± 0.060 mm (0.0011 ± 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
NOTICE:
Remove the Plastigage completely after the measurement.
(n) If replacing a bearing, select a new one having the same
number as marked on the connecting rod. There are 3
sizes of standard bearings, marked º1º, º2º and º3º ac\
-
cordingly.
Reference:
Standard bearing center wall thickness
Markmm (in.)
11.486 ± 1.490 (0.0585 ± 0.0587)
21.490 ± 1.494 (0.0587 ± 0.0588)
31.494 ± 1.498 (0.0588 ± 0.0590)
3. REMOVE PISTON SUB±ASSY W/CONNECTING ROD
(a) Using a ride reamer, remove all the carbon from the topof the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearing, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
http://vnx.su

A01191
A01038
Seal Packing
A62801
793
481062
15
A62806
Paint Mark
Front 90

14±52
±
ENGINE MECHANICAL CYLINDER BLOCK (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) Install the 2 thrust washers under the No. 3 journal posi- tion of the cylinder block with the oil grooves facing out-
ward.
(d) Apply engine oil to upper bearing and install the crank- shaft on the cylinder block.
(e) Apply a light coat of engine oil on the bolt threads, the bolt seats, and the bearings of the bearing cap sub±assy.
(f) Apply seal packing in the shape of bead (Diameter 2.5 ± 3.5 mm (0.08 ± 0.12 in.) consequently as shown in the il-
lustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the bearing cap sub±assembly within 3 min-
utes after applying seal packing.

Do not put into engine oil within 2 hours after the
installation.
(g) Using SST, tighten the bolts in several passes, in the se- quence shown, by the specified torque.
SST 09011±38121
Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
(h) Mark the front of the bearing cap sub±assy bolts with paint.
(i) Retighten the bearing cap sub±assy bolts by 90  as
shown in the illustration.
(j) Check that the painted mark is now at a 90  angle to the
front.
(k) Tighten 10 other bolts for the bearing cap.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
http://vnx.su