2003 TOYOTA AVENSIS check engine

17±18
±
LUBRICATIONOIL PUMP ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
64.INSTALL OIL RESERVOIR BRACKET NO.1 Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
65.INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
66.INSTALL RETURN TUBE SUB±ASSY Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
67.INSTALL IGNITION COIL ASSY
Torque: 9.0 N
m (92 kgf
cm,80 in.
lbf)
68.INSTALL VANE PUMP ASSY Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
69.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
70.INSTALL GENERATOR ASSY (See page 19±20)
71.INSTALL FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
72.INSTALL FUEL PUMP ASSY (See page 11±52)
73.INSTALL FUEL PIPE SUB±ASSY NO.1 (See page 11±52) SST 09023±12900
74.INSTALL FUEL TUBE SUB±ASSY (See page 11±33)
75.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY (See page 11±52)
76. ADD ENGINE OIL
77. CHECK FOR ENGINE OIL LEAKS
78. CHECK FUEL LEAK
79. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
80. INSTALL FRONT WHEEL RH
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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SST
A09583
Inward
Angle Sensor
±
LUBRICATIONOIL PUMP ASSY(1CD±FTV)
17±29
AVENSIS REPAIR MANUAL (RM1018E)
47.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located
on the camshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
48.INSTALL TIMING BELT IDLER SUB±ASSY NO.2 Torque: 47 N
m (479 kgf
cm,35 ft
lbf)
49.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
50.INSTALL TIMING BELT(See page 14±307)
51.CHECK VALVE TIMING(See page 14±307)
52.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
53.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
54.INSTALL TIMING BELT GUIDE(See page 14±307)
55.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
56.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
57.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
58. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59. INSTALL IDLER PULLEY SUB±ASSY
60.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
61. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
62.INSTALL INJECTOR DRIVER (See page 14±307)
63. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
64. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
65.ADD ENGINE OIL(See page 17±30)
66. CHECK FOR ENGINE OIL LEAKS
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170FR±01
B08737
A30890
±
LUBRICATIONOIL PUMP ASSY(1ZZ±FE/3ZZ±FE)
17±3
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Remove the oil pan drain plug and drain engine oil.
2.REMOVAL & INSTALLATION CHAIN SUB±ASSY (See page 14±49)
3.REMOVE CHAIN VIBRATION DAMPER NO.1
(a)Remove the 2 bolts and the chain vibration damper No. 1.
4.REMOVE OIL PUMP ASSY
(a)Remove the 5 bolts.
(b)Remove the oil pump assy and the gasket.
5.INSTALL OIL PUMP ASSY
(a)Place a new gasket on the cylinder block.
(b)Align the keyway of the oil pump drive rotor with the rect-angular portion of the crankshaft and slide the oil pump
into place.
(c)Install the oil pump with the 5 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
6.INSTALL CHAIN VIBRATION DAMPER NO.1
(a)Install the chain vibration damper No. 1 with 2 bolts. Torque: 9.0 N
m (92 kgf
cm,8.0 in.
lbf)
7.INSTALL OIL PAN DRAIN PLUG
(a)Clean and install the oil pan drain plug with a new gasket.
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
8.ADD ENGINE OIL (See page 17±4)
9.ADD ENGINE COOLANT (See page 16±7)
10. CHECK FOR ENGINE OIL LEAKS
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
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1807M±01
CHECK POWER SUPPLY TO IGNITION COIL WITHSENSOR (See page 18±9)
SPARK TEST
Replace crankshaft position sensor.
CHECK RESISTANCE OF CAMSHAFT POSITION
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL WITH IGNITER
Resistance: ColdHot
1,060 to 1,645

CHECK RESISTANCE OF CRANKSHAFT POSITION
Resistance: ColdHot
985 to 1,600
1,265 to 1,890

CHECK IGT SIGNAL FROM ECM
(See page 05±232)
REPAIR WIRING BETWEEN IGNITION COIL AND ECM Connect securely.
Check wiring between ignition switch to ignition coil with igniter.
Check ECM (See page 01±32)
NG
OK
OK
OK
OK NG
NG
NG
NG
NG
SENSOR (See page 18±9 )
835 to 1,400


IGNITER
CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER
AND PERFORM SPARK TEST AGAIN
OK
Replace ignition coil with igniter.
NG
OK
CONNECTOR
Replace camshaft position sensor.
±
IGNITIONIGNITION SYSTEM(1AZ±FE)
18±7
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION SYSTEM(1AZ±FE)
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean the temperature of the coils thems\
elves.ºColdº is from ±10C
(14F) to 50 C (122 F) and ºHotº is from 50 C (122 F) to 100 C (212 F).
1.INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
(a)Check for DTCs.
NOTICE:
If DTC is present, perform a troubleshooting in accordance with a proced\
ure for that DTC.
(b)Check that spark occurs. (1)Remove the cylinder head cover No. 1. (See page 14±106)
(2) Remove the ignition coils (with igniter).
(3) Using a 16mm (0.63 in) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil (with igniter) and connect the \
ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if spark occurs at each spark plug while engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil if it is given physical impact.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:
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B01301
IG0316
B02101
1.1 mm
B62019
18±10
±
IGNITION IGNITION SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Alternative inspection: (1) Quickly accelerate the engine to 4,000 rpm 5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (C).
(6) Reinstall the spark plug.
(c) Check the spark plug for any damage on its thread and insulator.
If there is damage, replace the spark plug. Recommended spark plug:
DENSO madeSK20R11
NGK madeIFR6A11
(d) Check the spark plug electrode gap.Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode
with a spark plug cleaner then dry it. Air pressure: Blow 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
3. INSPECT CAMSHAFT POSITION SENSOR
(a) Using an ohmmeter, measure the resistance between the terminals. RESISTANCE:
835 to 1,400  at cold
1,060 to 1,645 at hot
NOTICE:
ºColdº and ºHotº mean the temperature of the coils themselve\
s.ºColdº is from ± 10
C (14
F) to 50

C (122
F) and ºHotº is from 50
C (122
F) to 100
C (212
F).
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1807Q±01
CHECK POWER SUPPLY TO IGNITION COIL WITHSENSOR (See page 18±14)
SPARK TEST
Replace crankshaft position sensor.
CHECK RESISTANCE OF CAMSHAFT POSITION
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL WITH IGNITER
Resistance: ColdHot
1,060 to 1,645

CHECK RESISTANCE OF CRANKSHAFT POSITION
Resistance: ColdHot
985 to 1,600
1,265 to 1,890

CHECK IGT SIGNAL FROM ECM
(See page 05±439)
REPAIR WIRING BETWEEN IGNITION COIL AND ECM Connect securely.
Check wiring between ignition switch to ignition coil with igniter.
Check ECM (See page 01±32)
NG
OK
OK
OK
OK NG
NG
NG
NG
NG
SENSOR (See page 18±14)
835 to 1,400


IGNITER
CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER
AND PERFORM SPARK TEST AGAIN
OK
Replace ignition coil with igniter.
NG
OK
CONNECTOR
Replace camshaft position sensor.
18±12
±
IGNITIONIGNITION SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION SYSTEM(1AZ±FSE)
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean the temperature of the coils thems\
elves.ºColdº is from ±10C
(14F) to 50 C (122 F) and ºHotº is from 50 C (122 F) to 100 C (212 F).
1.INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
(a)Check for DTCs.
NOTICE:
If DTC is present, perform a troubleshooting in accordance with a proced\
ure for that DTC.
(b)Check that spark occurs. (1)Remove the cylinder head cover No. 1. (See page 14±186)
(2) Remove the ignition coils (with igniter).
(3) Using a 16mm (0.63 in) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil (with igniter) and connect the \
ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if spark occurs at each spark plug while engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil it is given physical impact.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:
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1807R±01
IG0147
Ohmmeter
Ground
A78638
A78639
18±14
±
IGNITION IGNITION SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT SPARK PLUG
NOTICE:

Do not use a wire brush for cleaning.

Do not attempt to adjust the electrode gap of a used
spark plug.

Spark plug should be replaced every 100,000 km
(60,000 miles).
(a) Check the electrode. (1) Using an ohmmeter, measure the insulation resis-
tance.
Correct insulation resistance: 10 M
or more
If the resistance is less then the specified value, proceed to step
(d).
HINT:
If the ohmmeter is not available, do the following inspection
instead.
(b) Alternative inspection: (1) Quickly accelerate the engine to 4,000 rpm 5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
If a kink or twist as shown in the illustration on the left is found
on the spark plug, replace it with a new one.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (e).
(6) Reinstall the spark plug.
(c) Check the spark plug for any damage on its thread and insulator.
If there is damage, replace the spark plug.
Recommended spark plug:
DENSO madeSK20BR11
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1807O±01
CHECK POWER SUPPLY TO IGNITION COIL WITHSENSOR (See page 18±3)
SPARK TEST
Replace crankshaft position sensor.
CHECK RESISTANCE OF CAMSHAFT POSITION
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL WITH IGNITER
Resistance: ColdHot
1,060 to 1,645

CHECK RESISTANCE OF CRANKSHAFT POSITION
Resistance: ColdHot
1,630 to 2,740
2,065 to 3,225

CHECK IGT SIGNAL FROM ECM
(See page 05±103)
REPAIR WIRING BETWEEN IGNITION COIL AND ECM Connect securely.
Check wiring between ignition switch to ignition coil with igniter.
Check ECM (See page 01±32)
NG
OK
OK
OK
OK NG
NG
NG
NG
NG
SENSOR (See page 18±3)
835 to 1,400


IGNITER
CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER
AND PERFORM SPARK TEST AGAIN
OK
Replace ignition coil with igniter.
NG
OK
CONNECTOR
Replace camshaft position sensor.
±
IGNITIONIGNITION SYSTEM(1ZZ±FE/3ZZ±FE)
18±1
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION SYSTEM(1ZZ±FE/3ZZ±FE)
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean the temperature of the coils thems\
elves.ºColdº is from ±10C
(14F) to 50 C (122 F) and ºHotº is from 50 C (122 F) to 100 C (212 F).
1.INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
(a)Check for DTCs.
NOTICE:
If DTC is present, perform a troubleshooting in accordance with a proced\
ure for that DTC.
(b)Check that spark occurs. (1)Remove the cylinder head cover No. 2. (See page 14±6)
(2) Remove the ignition coils (with igniter).
(3) Using a 16mm (0.63 in) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil (with igniter) and connect the \
ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if spark occurs at each spark plug while engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil it is given physical impact.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:
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