Page 2009 of 5135
1209J±02
A77127
Ohmmeter
Resistance
A77128No ContinuityOhmmeter
A77129
Vacuum
A77130
6V Vacuum 12±18
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT VACUUM REGULATING VALVE ASSY
(a) Inspect E±VRV for open circuit
(1) Using an ohmmeter, measure resistance between
the terminals.
Resistance:
10 to 14 at 20C (68F)
(b) Inspect E±VRV for ground
(1) Using an ohmmeter, check that there is no continu-
ity between each terminal and the body.
Specified condition : No continuity
(c) Inspect E±VRV for air tightness
(1) Apply vacuum to the vacuum output port. Check
that the needle of vacuum pump indicates an in-
crease of 66.7 kPa (500 mmHg, 19.7 in.Hg) or
more.
If the air tightness is not as specified, replace the E±VRV.
(d) Inspect E±VRV operation
(1) Apply about 4 dry batteries of 1.5V in series.
(2) Check that the need does not move when vacuum
is applied to the vacuum outlet port.
If operation is not as specified, replace the E±VRV.
Page 2010 of 5135
A82348
+B2
+B1EGR2
EGR1EGR4 EGR3
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
12±19
AVENSIS REPAIR MANUAL (RM1018E)
2. INSPECT EGR VALVE ASSY
(a) Using an ohmmeter, measure the resistance between the
terminals.
TerminalResistance at 20 C (68 F)
+B1 ± EGR119.6 1.4
+B1 ± EGR219.6 1.4
+B2 ± EGR319.6 1.4
+B2 ± EGR419.6 1.4
Page 2011 of 5135

1209I±02
± EMISSION CONTROLEGR SYSTEM (1CD±FTV)
12±17
AVENSIS REPAIR MANUAL (RM1018E)
EGR SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
HINT:
In a malfunction where the EGR system is always on, black smoke or white smoke may be emitted from the
exhaust pipe. If this occurs, inspect the EGR system as well.
1. INSPECT SEATING OF EGR VALVE
(a) Start the engine and check that it starts and runs at idle.
2. INSPECT HOT ENGINE CONDITION (WHEN USING HAND±HELD TESTER)
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Refer to the hand±held tester operator's manual for further details.
(d) Warm up the engine, the coolant temperature should be above 75C (109F) and bellow 90C
(194F).
(e) Check that the AFM reading is 5ega8 g/s with the engine idling.
(f) Operate the EGR valve with a hand±held tester. Regulate the valve opening angle to 0, and check that
the AFM reading is 11ega17 g/s..
If the AFM reading is out of range in either (e) or (f), replace the EGR valve.
If the AFM is out of range in both (e) and (f), replace the air flow meter (air cleaner) and check the EGR valve
operation again.
3. INSPECT HOT ENGINE CONDITION (WHEN NOT USING HAND±HELD TESTER)
(a) Install the vacuum gauge.
(1) Using a 3±way connector, connect a vacuum gauge to the hose between the intake manifold and
the turbo pressure sensor.
(b) Warm up the engine, the coolant temperature should be above 75C (109F) and bellow 90C
(194F).
(c) Check that the vacuum gauge indicates about more than 2.5 kPa (19 mmHg 0.7 in Hg).
(d) Stop the engine (IG OFF), remove the EGR valve connector, restart the engine, and check that load
under idling is less than 2.5 kPa (19 mmHg 0.7 in Hg).
If the load pressure exceeds the above value, replace the EGR valve.
Page 2012 of 5135
141CK±01
A78459
A76713
A64023
A65078
14±64
±
ENGINE MECHANICAL CAMSHAFT(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE UNDER COVER RH (See page 14±27) 3. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove and the 2 screw and 2 clips and detach the en-gine under cover No.2.
4. DISCONNECT COIL, IGNITION
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.
5. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head cover.
Page 2013 of 5135
A64058
A64856
A60622
A01045
A64005
±
ENGINE MECHANICAL CAMSHAFT(1ZZ±FE/3ZZ±FE)
14±65
AVENSIS REPAIR MANUAL (RM1018E)
6.DISCONNECT VENTILATION HOSE NO.2
(a)Disconnect the ventilation hose from the cylinder head
cover.
7.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts, and 3 clamp brackets.
(b)Remove the cylinder head cover.
8.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
9. REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
10. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
11. REMOVE ENGINE MOUNTING INSULATOR SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine. Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.
Page 2014 of 5135

A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
A11858
A62186
Paint Mark
A62178
Push 14±66
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
12. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley to align the timing notch with
timing mark º0º of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360) and align the
marks as above.
13. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, then remove the V±ribbed belt
tensioner.
HINT:
Jack up and down to remove the bolt.
14. REMOVE CAMSHAFT
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and the camshaft
timing sprockets.
(c) Remove the 2 nuts and the chain tensioner.
Page 2015 of 5135
A62187
Hold
Tighten
A62188
24 5 3 1
A32124
A6218924 31
A32125
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
14±67
AVENSIS REPAIR MANUAL (RM1018E)
(d) Hold the camshaft with a wrench, loosen the camshaft
timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.
(e) Using several steps, loosen the camshaft bearing cap
bolts on No. 2 camshaft in the sequence shown in the il-
lustration. Remove the bearing caps.
(f) Remove the camshaft timing gear as shown in the illustra-
tion.
(g) Using several steps, loosen the camshaft bearing cap
bolts on camshaft in the sequence shown in the illustra-
tion. Remove the bearing caps.
(h) Remove the camshaft as holding the timing chain.
Page 2016 of 5135

A32556
A62190
Advance
Side Path Retard Side
Path
Open
Close
Rubber Vinyl Tape Open Close
A62191
Advanced
Side Path Retard
Side Path
14±68
± ENGINE MECHANICALCAMSHAFT (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(i) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
15. INSPECT CAMSHAFT TIMING GEAR ASSY
(a) Check the lock of camshaft timing gear.
(1) Clamp the camshaft in a vice, and confirm the cam-
shaft timing gear is locked.
NOTICE:
Be careful not to damage the camshaft.
(b) Release lock pin.
(1) Cover 4 oil paths of the cam journal with vinyl tape
as shown in the illustration.
HINT:
The one of the 2 glooves on the cam journal is for retards (up-
per) and the rest is for advances (lower). Each groove has the
2 oil paths. Plug one of the oil paths for each groove with rubber
pieces before wrapping the cam journal with the tape.
(2) Punctuate the tape for the advance oil path and for
the retard oil path in the opposite side from the ad-
vance as shown in the illustration.
(3) Put air pressure into two broken paths (the advance
side path and the retard side path) with about 150
kPa {1.5 kgfcm}.
CAUTION:
Cover the pathes with shop rag to avoid oil splashing.