Page 4561 of 5135
120DD−01
32 1
A85764
EGLS
E2VC
− EMISSION CONTROLEGR SYSTEM (1CD−FTV)(From September, 2003)
12−9
AVENSIS Supplement (RM1045E)
INSPECTION
1. INSPECT EGR VALVE POSITION SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween terminals 1 (VC) and 2 (E2).
Resistance: 4.0 to 6.0 kat 20_C (68_F)
If the result is not as specified, replace the EGR valve position
sensor.
2. INSPECT EGR VALVE ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance between the terminals.
Resistance: 6.5 to 7.5at 20_C (68_F)
If the result is not as specified, replace the EGR valve assembly.
Page 4562 of 5135

120DC−01
A86428
1
2
E2
THG
A87894
+B HT
AF+
AF
− 2
3
4 1
A92423
W/HID:
HT
AF+
+B
AF − 1
2
3
4
−
EMISSION CONTROL EMISSION CONTROL SYSTEM (1CD −FTV)(From
September, 2003)12 −7
AVENSIS Supplement (RM1045E)
INSPECTION
1. I NSPECT EXHAUST F UEL ADDI TI O N I NJECTO R
ASSY
(a) Inspect the resistance. (1) Using an ohmmeter, measure the resistance be- tween the terminals.
Resistance: 11.6 to 12.4 at 20 _C (68 _F)
If the result is not as specified, replace the exhaust fuel addition
injector assembly (see page 14 −166).
2. INSPECT EXHAUST GAS TEMPERATURE SENSOR
(a) Inspect the resistance. (1) Using an ohmmeter, measure the resistance be-
tween the terminals.
Resistance: 242 k at 20 _C (68 _F)
If the result is not as specified, replace the exhaust gas temper-
ature sensor (see page 14 −108).
3. INSPECT AIR −FUEL RATIO SENSOR
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be- tween the terminals.
Resistance:
Tester ConnectionResistance
1 (HT) − 2 (+B)0.8 to 1.4 at 20 _ C (68 _ F)
1 (HT) − 4 (AF −)10 k or higher
If the result is not as specified, replace the air −fuel ratio sensor
(see page 15 −6) .
Page 4563 of 5135
1111 F−01
A864322 Claws
− FUELFUEL CONTROL SWITCH (1CD−FTV)(From
September, 2003)11−73
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FUEL CONTROL SWITCH
(a) Separate the 2 claw fittings, then remove the fuel control
switch.
(b) Disconnect the fuel control switch connector.
2. INSTALL FUEL CONTROL SWITCH
HINT:
The installation is in the reverse order of the removal.
Page 4564 of 5135
1111 E−01
A86431
Fuel Control Switch
− FUELFUEL CONTROL SWITCH (1CD−FTV)(From
September, 2003)11−71
AVENSIS Supplement (RM1045E)
FUEL CONTROL SWITCH (1CD−FTV)(From September,
2003)
LOCATION
Page 4565 of 5135
A87892
ECM
SSW Fuel Control Switch
W−BL
R−W
From Battery
IPE105
6
3 2 11−72
− FUELFUEL CONTROL SWITCH (1CD−FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
Page 4566 of 5135

110UC−02
A93407SST
A93406
SST
−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)11 −67
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DRAIN ENGINE COOLANT (See page 16 −19)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE COVER SUB −ASSY NO.1
(a) Remove the 5 nuts and engine cover.
4. REMOVE RADIATOR RESERVE TANK SUB −ASSY (See Pub.No. RM1018E on page 16 −50)
5. REMOVE FUEL INLET PIPE SUB −ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and injection pump with vinyl tape to prevent dust from be-
ing introduced.
(a) Using SST, remove the fuel inlet pipe from the common rail.
SST 09023 −12700
(b) Using SST, remove the fuel inlet pipe from the injection
pump.
SST 09023 −12700
6. REMOVE FUEL PIPE NO.3 (See page 11 −46)
SST 09023 −12700
7. REMOVE INJECTION PIPE SUB −ASSY NO.1
(a) Remove the 2 nuts and 2 upper injection pipe clamps from the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023 −12700
(c) Using SST, remove the injection pipe from the injector side.
SST 09023 −12700
(d) After removing the fuel pipe, to prevent dust or foreign ob-
jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
8. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
9. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
Page 4567 of 5135

A79154
A87959
30 cmSST
(11.81 in.)
11
−68
−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
10. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
11. DISCONNECT FUEL HOSE NO.4
(a) Disconnect the fuel hose from the common rail.
12. REMOVE INTAKE MANIFOLD INSULATOR NO.1 (See page 11 −58)
13. REMOVE COMMON RAIL ASSY
(a) Disconnect the engine wire connector from the bracket.
(b) Remove the 2 bolts and common rail.
14. INSTALL COMMON RAIL ASSY Torque: 43 N m (438 kgf cm, 32 ft lbf)
15. INSTALL INTAKE MANIFOLD INSULATOR NO.1 (See page 11 −58)
16. INSTALL INJECTION PIPE SUB −ASSY NO.1
NOTICE:
SIn case of replacing the common rail, the injector
pipes must be replaced, too.
SWhen assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and the vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
Page 4568 of 5135

−
FUEL COMMON RAIL ASSY (1CD −FTV)(From September,
2003)11 −69
AVENSIS Supplement (RM1045E)
(c) Using SST, tighten the nut of the injection pipe to the com-
mon 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 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.
(d) Using SST, tighten the nut of the injection pipe to the injec- tor 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.
17. INSTALL INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
18. INSTALL INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
19. INSTALL INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
20. INSTALL FUEL PIPE NO.3 (See page 11 −46)
SST 09023 −12700