2003 TOYOTA AVENSIS oxygen

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INTRODUCTION TERMS
01±39
AVENSIS REPAIR MANUAL (RM1018E)Abbreviations Meaning
H±FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O2SOxygen Sensor
O/DOverdrive
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±
INTRODUCTION TERMS
01±43
AVENSIS REPAIR MANUAL (RM1018E)
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
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031FP±01
03±10
±
SERVICE SPECIFICATIONS EMISSION CONTROL
AVENSIS REPAIR MANUAL (RM1018E)
EMISSION CONTROL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Heated oxygen sensor
Resistance Bank 1 sensor 1 1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10  at 20
C (68
F)
No continuity
Heated oxygen sensor
Resistance Bank 1 sensor 2 1 (HT1A) ± 2 (+B)
1 (HT1A) ± 4 (E1)
5 to 10  at 20
C (68
F)
No continuity
Vacuum switching valve
Resistance at 20
C (68
F)
26 to 30 
1AZ±FE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
26 to 30 
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16  at 20
C (68
F)
No continuity
Air fuel ratio sensor
Resistance 1 (HT) ± 2 (+B) 1 (HT) ± 2 (+B)
1 (HT) ± 4 (E1)
1.8 to 3.4 at 20
C (68
F)
5.0 to 7.5 at 500
C (932
F)
No continuity
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
26 to 30 
Heated oxygen sensor
Resistance 1 (HT) ± 2 (+B)
Resistance 1 (HT) ± 4 (E1)
11 to 16  at 20
C (68
F)
No continuity
1CD±FTV:
EGR valve assy
Resistance +B1 ± EGR1 +B1 ± EGR2
+B1 ± EGR3
+B1 ± EGR4
19.6
1.4  at 20
C (68
F)
19.6
1.4  at 20
C (68
F)
19.6
1.4  at 20
C (68
F)
19.6
1.4  at 20
C (68
F)
Vacuum switching valve assy
Resistance at 20
C (68
F)
10 to 14 
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031E3±02
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SERVICE SPECIFICATIONS EXHAUST
03±23
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy front x Exhaust pipe assy tail4344032
Heated oxygen sensor x Exhaust pipe assy front4444933
Floor panel brace front x Body3030222
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy center x Exhaust pipe assy front4344032
Exhaust pipe assy tail x Exhaust pipe assy center4344032
Floor panel brace front x Body3030222
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Exhaust pipe assy front x Exhaust manifold4344032
Exhaust pipe assy front x Tail pipe assy4344032
Floor panel brace front x Body3030222
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110U5±01
A78493
A80060
w/o HID Sensor:
w/ HID Sensor:
(c)
(d)
(c)
±
FUELFUEL TANK ASSY(GASOLINE)
11±93
AVENSIS REPAIR MANUAL (RM1018E)
Removal & Installation and Disassembly & Reassembly
1.DISCHARGE FUEL SYSTEM PRESSURE
HINT:

1ZZ±FE/3ZZ±FE: 11±1

1AZ±FE: 11±15

1AZ±FSE: 11±30
2.REMOVE REAR SEAT CUSHION ASSY (SEAT FIXED TYPE) (See page 72±32)
3.REMOVE COVER, RR FLOOR SERVICE HOLE (See page 11±85)
4.DISCONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
(See page 11±85)
5.DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY (See page 11±85)
6.DISCONNECT FUEL EVAPORATION TUBE SUB±ASSY NO.2 (See page 11±85)
7.REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY (See page 11±85)
SST 09808±14010
8. DRAIN FUEL
9. REMOVE FRONT FLOOR FOOTREST (W/O HID SENSOR)
10.REMOVE FLOOR PANEL BRACE FRONT (See page 15±2)
11. REMOVE EXHAUST PIPE ASSY CENTER(1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Using a clip remover, remove the 2 clips. (w/o HID Sensor)
(b) Open the floor carpet. (w/o HID Sensor)
(c) Disconnect the heated oxygen sensor connector.
(d) Remove the grommet. (w/o HID Sensor)
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A81618
Push
2
1Retainer
A77857
A78440
New Gasket
A77857
±
FUEL FUEL TANK ASSY (GASOLINE)
11±99
AVENSIS REPAIR MANUAL (RM1018E)
30. CONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Push in the fuel tube connector to the pipe until it makes
ºclickº sound, and then push up the retainer to the claws
lock.
NOTICE:

Check if there is any damage or foreign objects on the
connected part.

After connecting, check if the fuel tube connector and
the pipe are securely connected by pulling on them.
31. CONNECT FUEL TANK RETURN TUBE (1AZ±FSE ENGINE TYPE)
32. CONNECT FUEL TANK TO FILLER PIPE HOSE
33. CONNECT BREATHER TUBE FUEL HOSE
34. INSTALL PARKING BRAKE CABLE ASSY NO.3
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
35. INSTALL PARKING BRAKE CABLE ASSY NO.2
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
36. INSTALL FUEL TANK PROTECTOR NO.1 Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
37. INSTALL EXHAUST PIPE ASSY CENTER (1ZZ±FE/3ZZ±FE ENGINE TYPE)
(a) Compression spring inspection (1) Using vernier calipers, measure the free length ofthe compression spring.
Minimum length:
41.5 mm (1.634 in.) for front x manifold
38.5 mm (1.516 in.) for front x tail
If the free length is less than minimum, replace the compression
spring.
(b) Install each new gasket to the exhaust manifold and the
exhaust pipe front as shown in the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup- ports
(d) Tighten the 4 compression springs and 4 bolts. Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
(e) Install the grommet. (w/o HID Sensor)
(f) Connect the heated oxygen sensor connector.
(g) Install the floor carpet with the 2 clips. (w/o HID Sensor)
38. INSTALL EXHAUST PIPE ASSY CENTER (1AZ±FE/1AZ±FSE ENGINE TYPE)
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length ofthe compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.
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A60559
+BHT
Bank 2 Sensor 1:
E1
A62378
+B
HT
E1

 
12±10
±
EMISSION CONTROL EMISSION CONTROL SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Bank 2 Sensor 1: (1) Using an ohmmeter, measure the resistance be-tween the terminals.
Resistance:
Terminal No.Resistance
1 (HT) ± 2 (+B)1.8 to 3.4
at 20
C (68
F)
1 (HT) ± 2 (+B)5.0 to 7.5
at 500
C (932
F)
1 (HT) ± 4 (E1)No Continuity
If the resistance is not as specified, replace the sensor.
6. INSPECT HEATED OXYGEN SENSOR
(a) Using an ohmmeter, measure the resistance between the
terminals.
Resistance:
Terminal No.Resistance
1 (HT) ± 2 (+B)11 to 16
at 20
C (68
F)
1 (HT) ± 4 (E1)No Continuity
If the resistance is not as specified, replace the sensor.
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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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