2005 TOYOTA AVENSIS check engine

A66060ECM ConnectorEPA2 (
−) VPA (+)
VPA2 (+)
EPA (−)
E9
−
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD−FTV)(From September, 2003)
10 −21
AVENSIS Supplement (RM1045E)
3. I NSPECT ACCELERATO R PEDAL PO SI TI O N SEN-
SOR
(a) If you have the hand −held tester:
Inspect the accelerator pedal position sensor.
(1) Connect the hand −held tester to the DLC3.
(2) Turn the ignition switch to ON.
(b) Select the item ”DIAGNOSIS / OBD / MOBD / DATE LIST” on the hand −held tester.
(1) Check that the voltage (ACCEL POS) of DATA LIST shows the standard value.
Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depressed: 3.0 to 4.6 V
(2) Check that the voltage (ACCEL POS #2) of DATA LIST shows the standard value.
Accelerator pedal released: 0.9 to 2.3 V
Accelerator pedal depressed: 3.4 to 5.0 V
If the result is not as specified, check the accelerator pedal posi-
tion sensor (see page 10 −22), wiring and ECM.
(c) If you have no hand −held tester:
Inspect the accelerator pedal position sensor.
(1) Turn the ignition switch to ON.
(2) Measure the voltage between the specified termi- nals of the E9 ECM connector.
Accelerator Pedal PositionTester ConnectionSpecified ConditionTester ConnectionSpecified Condition
ReleasedVPA (E9 −22)
− EPA (E9 −28)0.5 to 1.1 VVPA2 (E9 −23)
− EPA2 (E9 −29)0.9 to 2.3 V
DepressedVPA (E9 −22)
− EPA (E9 −28)3.0 to 4.6 VVPA2 (E9 −23)
− EPA2 (E9 −29)3.4 to 5.0 V
If the result is not as specified, check the accelerator pedal posi-
tion sensor (see page 10 −22), wiring and ECM.

−
ENGINE CONTROL SYSTEM KNOCK SENSOR (2AZ−FSE)
10 −17
AVENSIS Supplement (RM1045E)
25. INSTALL FUEL PUMP ASSY (See page 11 −24)
26. INSTALL FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
27. INSTALL FUEL HOSE
28. INSTALL FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
29. INSTALL THROTTLE BODY ASSY (See page 10 −8)
30. INSTALL AIR CLEANER CAP SUB −ASSY (See page 10 −8)
31. CONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL) Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
32. ADD ENGINE COOLANT (See page 16 −7)
33. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −1)
34. CHECK FOR FUEL LEAKS (See page 11 −4)
35. CHECK FOR ENGINE OIL LEAKS
36. INSTALL ENGINE COVER SUB −ASSY NO.1 ( See page 10 −8)
37. INSTALL ENGINE ROOM COVER SIDE
38. INSTALL RADIATOR SUPPORT OPENING COVER

A61190
90_ 90
_
90_90
_ 90
_
90_
Paint Mark
Front
A85427
TDC Mark
Dot Mark
90 _
A85942
New O −ring
14 −172−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(d) Mark the front of the cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 _ in the same se-
quence as step (c).
(f) Retighten the cylinder head bolts by an additional 90 _ in
the same sequence as step (c).
(g) Retighten the cylinder head bolts by one more additional
90_ in the same sequence as step (c).
(h) Check that each painted mark is now at the intake man-
ifold side.
82. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Using the crankshaft pulley bolt, turn the crankshaft to set the dot mark of the crankshaft timing gear at the position
of 90_ BTDC.
NOTICE:
If the timing belt is disengaged, the crankshaft timing gear
placed at wrong angle can cause contact of the piston head
with the valve head.
83. INSTALL CAMSHAFT (See page 14 −151)
84. INSTALL NO.2 CAMSHAFT (See page 14 −151)
85. REMOVE CAMSHAFT OIL SEAL (See page 14 −151)
86. INSTALL CAMSHAFT OIL SEAL (See page 14 −151)
SST 09223 −46011
87. INSTALL CAMSHAFT OIL SEAL RETAINER (See page 14 −151)
88. I NSTALL EXHAUST F UEL ADDI TI O N I NJECTO R ASSY
(a) Install a new gasket to the cylinder head.
(b) Install a new O −ring to the injector.
(c) Apply a light coat of engine oil to the O −ring on the injec-
tor.
(d) Install the addition injector and nozzle holder clamp.
(e) Using a Torx socket wrench (T40), install the Torx screw. Torque: 12 N
m (117 kgf
cm, 8.5 ft
lbf)
NOTICE:
Be careful that the tools do not interfere with the resin part
when installing.
89. INSTALL CAMSHAFT TIMING PULLEY (See page 14 −151)
SST 09960 −10010 (09962 −01000, 09963 −01000)
90. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
91. INSTALL INJECTOR ASSY (See page 11 −46)
92. INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 14 −151)
SST 09992 −00242

A09663
:Seal Packing
A87959
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −173
AVENSIS Supplement (RM1045E)
93. INSTALL CYLINDER HEAD COVER SUB −ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as illustrated. 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)
94. INSTALL NOZZLE HOLDER SEAL
(a) Install 4 new nozzle holder seals.
95. INSTALL NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
96. INSTALL VACUUM PUMP ASSY (See page 14 −108)
97. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
When assembling the pipes, perform the operation with the
engine cold at room temperature.
(a) Remove the vinyl or plastic bag from the injector and the vinyl tape from the common rail.
(b) Install the 2 lower injection pipe clamps to the intake man- ifold.
(c) Temporarily install the injection pipe.
(d) Using SST, tighten the nut of the injection pipe on the common rail side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
SUse a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
SAfter the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.

14−174−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
(e) Using SST, tighten the nut of the injection pipe on the in- jector side.
SST 09023 −12700
Torque:
For used pipe:
36 N
m (372 kgf
cm, 27 ft
lbf) with SST
40 N
m (408 kgf
cm, 30 ft
lbf) without SST
For new pipe:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the injection pipe is reassembled, check that the
used pipe has no deflection and is installed properly. If it
has deflection or could not be installed properly, replace
the used pipe with a new pipe.
(f) Install the 2 upper injection pipe clamps.
98. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
99. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
100. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
101. INSTALL FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
102. INSTALL FUEL INLET PIPE SUB −ASSY
NOTICE:
SIn case of replacing the cylinder head gasket, the fuel
inlet pipe must be replaced, too.
SWhen assembling the pipe, perform the operation
with the engine cold at room temperature.
(a) Temporarily install a new fuel inlet pipe.

A87960
Fulcrum Length
30 cm (11.81 in.)
SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −175
AVENSIS Supplement (RM1045E)
(b) Using SST, tighten the nut of the fuel inlet pipe on the
common rail side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
(c) Using SST, tighten the nut of the fuel inlet pipe on the pump side.
SST 09023 −12700
Torque:
31 N
m (316 kgf
cm, 23 ft
lbf) with SST
34 N
m (347 kgf
cm, 25 ft
lbf) without SST
HINT:
S Use a torque wrench with the fulcrum length of 30 cm
(11.81 in.).
S After the inlet pipe is reassembled, check that the used
pipe has no deflection and is installed properly. If it has
deflection or could not be installed properly, replace the
used pipe with a new pipe.
103. INSTALL TURBOCHARGER SUB −ASSY (See page 13 −12)
104. INSTALL TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
105. INSTALL TURBOCHARGER STAY (See page 13 −12)
106. INSTALL MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
107. INSTALL MANIFOLD STAY NO.2 (See page 13 −12)
108. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
109. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
110. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
111. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
112. INSTALL EGR PIPE INSULATOR (See page 13 −12)
113. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
114. INSTALL TURBO INSULATOR NO.1 (See page 13 −12)
115. INSTALL TURBO INSULATOR NO.2 (See page 13 −12)
116. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
117. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
118. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
119. INSTALL HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
120. INSTALL HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
121. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)

14−176−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
122. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
SST 09960 −10010 (09962 −01000, 09963 −01000)
123. INSTALL TIMING BELT (See page 14 −138)
124. CHECK VALVE TIMING (See page 14 −138)
125. INSTALL TIMING CHAIN COVER PLATE (See page 14 −138)
126. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
127. INSTALL TIMING BELT GUIDE (See page 14 −138)
128. INSTALL TIMING BELT NO.1 COVER (See page 14 −138)
129. INSTALL TIMING BELT NO.2 COVER (See page 14 −138)
130. INSTALL IDLER PULLEY SUB −ASSY (See page 14 −138)
131. INSTALL CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021
132. INSTALL ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
133. INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14 −108)
134. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
135. INSTALL INJECTOR DRIVER (See page 14 −108 )
136. INSTALL AIR TUBE NO.1 (See page 14 −108)
137. INSTALL AIR TUBE NO.2 (See page 14 −108)
138. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY (See page 14 −108)
139. INSTALL BATTERY (See page 14 −108)
140. INSTALL AIR CLEANER ASSY (See page 14 −108)
141. INSTALL VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
142. INSTALL ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
143. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
144. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
145. ADD ENGINE COOLANT (See page 16 −19)
146. CHECK FOR FUEL LEAKS (See page 11 −46)
147. CHECK FOR ENGINE OIL LEAKS
148. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
149. CHECK FOR EXHAUST GAS LEAKS

A85428
Seal Width
2to4mm
(0.08 to 0.16 in.)Seal Packing
A62592
SST
A85760
90_
14
−156
−
ENGINE MECHANICAL CAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826 −00080 or equivalent
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing.
(3) Immediately remove the nozzle from the tube, then reinstall the cap.
(c) Install the oil seal retainer with the 4 bolts. Tighten the 4 bolts uniformly in several steps.
Torque: 9.8 N
m (100 kgf
cm, 7.2 ft
lbf)
52. 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, then slide the pulley into place.
(c) Using SST, install the pulley bolt. SST 09960 −10010 (09962 −01000, 09963 −01000)
Torque: 88 N
m (899 kgf
cm, 65 ft
lbf)
53. INSTALL CAMSHAFT POSITION SENSOR (See page 14 −108)
54. INSTALL INJECTOR ASSY 55. INSTALL NOZZLE LEAKAGE PIPE ASSY
(a) Remove the bolt which is tightened at the center of thecamshaft bearing cap No. 4.
(b) Install the nozzle leakage pipe and 4 new gaskets.
NOTICE:
When installing the gaskets, pay attention to the mounting
orientation. Install the gasket so that the joint of the gasket
comes within the ranges shown in the illustration.
(c) Apply a light coat of engine oil to the 4 hollow screws and bolt.
(d) Tighten the 4 hollow screws and bolt by hand.
(e) Tighten the 4 hollow screws and bolt. Torque:
16 N
m (163 kgf
cm, 12 ft
lbf) for hollow screw
20 N
m (204 kgf
cm, 15 ft
lbf) for flange bolt
NOTICE:
In any case, when the torque exceeds the upper limit, re-
place the leakage pipe hollow screw and gaskets with new
ones.
(f) Check that there are no leaks from the nozzle leakage pipe connection.