Page 4609 of 5135

100M2−01
A75903
Air
A66060
VG
EVGE12 ECM Connector
−
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD−FTV)(From September, 2003)
10 −19
AVENSIS Supplement (RM1045E)
ECD SYSTEM (1CD −FTV)(From September, 2003)
ON −VEHICLE INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) If you have the hand −held tester:
Check the operation.
(1) Connect the hand −held tester to the DLC3.
(2) Turn the ignition switch to ON.
(3) Select the item ”DIAGNOSIS / OBD / MOBD / DATA
LIST” on the hand −held tester.
(4) Blow air into the mass air flow (MAF) meter, then
check that the MAF reading in DATA LIST fluctu-
ates.
If the operation is not as specified, check the MAF meter
(see page 10 −22), wiring and ECM.
(b) If you have no hand −held tester:
Check the operation.
(1) Turn the ignition switch to ON.
(2) Connect the positive tester probe of a voltmeter to
terminal VG of the ECM, and the negative tester
probe of the voltmeter to terminal EVG of the ECM.
(3) Blow air into the MAF meter, then check that the voltage fluctuates.
If the operation is not as specified, check the MAF meter
(see page 10 −22), wiring and ECM.
2. INSPECT INTAKE SHUTTER
(a) Listen to the operating sounds of the throttle control mo- tor.
(1) Turn the ignition switch to ON.
(2) Listen to the operating sounds while turning the ac-
celerator pedal position sensor lever.
If a collision sound is heard, check the throttle control motor.
If no sound is heard, check the wire harness and ECM.
(b) If you have the hand −held tester:
Inspect the throttle position sensor.
(1) Connect the hand −held tester to the DLC3.
(2) Turn the ignition switch to ON.
(3) Select the item ”DIAGNOSIS / OBD / MOBD / DATE LIST” on the hand held −tester.
Page 4610 of 5135

A66060
E12
ECM Connector
E1
LUSL
A92422
Signal Waveform
10 msec./Dvision
10
−20
−
ENGINE CONTROL SYSTEM ECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(4) When turning the accelerator pedal position sensor lever t o t he f ull − open posit ion, check t hat t he
t hr ot t le v alve opening per cent age ( THRO TTLE
POS) of DATA LIST shows the standard value.
Standard throttle valve opening percentage:
60 % or higher
If the operation is not as specified, check the accelerator pedal
position sensor (see page 10 −22), wiring and ECM.
(c) If you have no hand −held tester:
(1) Inspect the throttle position sensor using a oscillo- scope.
(2) During idling, check the waveform between the spe- cified terminals of the E12 ECM connectors.
Standard:
Tester ConnectionSpecified Condition
LUSL (E12 −4) − E1 (E12 −7)Correct waveform is as shown on the left
If the operation is not as specified, check the accelerator pedal
position sensor (see page 10 −22), wiring and ECM.
(d) Inspect the air assist system.
(1) Start the engine, then check that the check engine warning light does not light up.
(2) Allow the engine to warm up to the normal operating
temperature.
(3) Turn the A/C compressor ON to OFF, then check the
idle speed (see page 14 −87).
Idle speed (transmission in neutral): 800 á50 rpm
If the result is not as specified, check the wiring and ECM.
NOTICE:
Perform the inspection under condition without electrical
load.
(e) After taking the above steps (b) to (c), perform the driving test.
(f) Check that there is no sense of incongruity.
Page 4611 of 5135

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.
Page 4612 of 5135

100LZ−01
A88269
(a)
(b)
A78436
10 _
10 _ Upper
Engine
Front
10
−16
−
ENGINE CONTROL SYSTEM KNOCK SENSOR (2AZ−FSE)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11 −1)
2. REMOVE RADIATOR SUPPORT OPENING COVER (See page 10 −8)
3. REMOVE ENGINE ROOM COVER SIDE (See page 10 −8)
4. DISCONNECT ENGINE WIRE NO.3 (BATTERY NEGATIVE TERMINAL)
5. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 10 −8)
6. DRAIN ENGINE COOLANT (See page 16 −7)
7. REMOVE AIR CLEANER CAP SUB −ASSY (See page 10 −8)
8. REMOVE THROTTLE BODY ASSY (See page 10 −8)
9. REMOVE FUEL TUBE SUB −ASSY (See page 11 −24)
SST 09617 −24011
10. REMOVE FUEL HOSE (See page 11 −24)
11. REMOVE FUEL PIPE SUB −ASSY NO.1 (See page 11 −24)
SST 09023 −12900
12. REMOVE FUEL PUMP ASSY (See page 11 −24)
13. REMOVE CHARCOAL CANISTER ASSY (See page 11 −13)
14. REMOVE VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) (See page 11 −13)
15. REMOVE INTAKE MANIFOLD (See page 11 −4)
16. REMOVE SURGE TANK STAY NO.1 (See page 11 −13)
17. REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11 −13)
18. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Remove the nut, then remove the knock sensor.
19. INSTALL KNOCK SENSOR
(a) Install the knock sensor with the nut as shown in the il- lustration.
Torque: 20 N m (204 kgf cm, 15 ft lbf)
(b) Connect the knock sensor connector.
20. INSTALL INTAKE MANIFOLD INSULATOR NO.2
21. INSTALL SURGE TANK STAY NO.1 ( See page 11 −13)
22. INSTALL INTAKE MANIFOLD (See page 11 −13)
23. INSTALL VACUUM SENSOR ASSY (LHD STEERING POSITION TYPE) (See page 11 −13)
24. INSTALL CHARCOAL CANISTER ASSY
Page 4613 of 5135
−
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
Page 4614 of 5135

141NM−01
14 −166−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE RADIATOR SUPPORT OPENING COVER
6. REMOVE ENGINE ROOM COVER SIDE
7. DRAIN ENGINE COOLANT (See page 16 −19)
8. DRAIN ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
9. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
10. REMOVE VACUUM RESERVOIR SUB −ASSY (See page 14 −108)
11. REMOVE AIR CLEANER ASSY (See page 14 −108)
12. REMOVE BATTERY
13. REMOVE AIR TUBE NO.2 (See page 14 −108)
14. REMOVE AIR TUBE NO.1 (See page 14 −108)
15. REMOVE INJECTOR DRIVER (See page 14 −108)
16. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See Pub. No. RM1018E on page 14 −269)
17. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
18. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
19. DISCONNECT ENGINE WIRE (See page 14 −138)
20. DISCONNECT VACUUM HOSE (See page 14 −108)
21. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSY(See page 14 −108)
22. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
23. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
24. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
25. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
26. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
27. REMOVE TIMING BELT GUIDE
28. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
29. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
30. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
31. REMOVE TIMING BELT (See page 14 −138)
HINT:
If reusing the timing belt, draw an arrow on the timing belt which indicates the engine revolution direction
and put match marks on the pulleys and timing belt.
32. REMOVE FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
33. REMOVE HEATER PUMP ASSY (W/ COLD AREA) (See page 13 −12)
34. REMOVE HEATER BRACKET (W/ COLD AREA) (See page 13 −12)
35. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
36. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
37. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13 −12)
38. DISCONNECT RADIATOR HOSE INLET
39. DISCONNECT HEATER INLET WATER HOSE
40. DISCONNECT HEATER OUTLET WATER HOSE
41. DISCONNECT FUEL PIPE TO FUEL TUBE FUEL HOSE
42. DISCONNECT OIL COOLER HOSE
Page 4615 of 5135

A93407SST
−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)14 −167
AVENSIS Supplement (RM1045E)
43. REMOVE TURBO INSULATOR NO.2 (See page 13 −12)
44. REMOVE TURBO INSULATOR NO.1 (See page 13 −12)
45. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See page 13 −12)
46. REMOVE EGR PIPE INSULATOR (See page 13 −12)
47. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
48. REMOVE EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
49. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
50. REMOVE VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
51. REMOVE MANIFOLD STAY NO.2 (See page 13 −12)
52. REMOVE MANIFOLD STAY (See page 13 −12)
53. REMOVE MANIFOLD CONVERTER SUB −ASSY (See page 13 −12)
54. REMOVE TURBOCHARGER STAY (See page 13 −12)
55. REMOVE TURBO WATER HOSE NO.1 (See page 13 −12)
56. REMOVE TURBO WATER HOSE NO.2 (See page 13 −12)
57. SEPARATE TURBO OIL INLET PIPE SUB −ASSY (See page 13 −12)
58. REMOVE TURBOCHARGER SUB −ASSY (See page 13 −12)
59. REMOVE CAMSHAFT POSITION SENSOR (See page 14 −108)
60. REMOVE CAMSHAFT TIMING PULLEY (See page 14 −151)
SST 09960 −10010 (09962 −01000, 09963 −01000)
61. REMOVE FUEL INLET PIPE SUB −ASSY
(a) Using SST, remove the fuel inlet pipe from the common rail side.
SST 09023 −12700
(b) Using SST, remove the fuel inlet pipe from the pump side.
SST 09023 −12700
NOTICE:
After removing the fuel pipe, cover the common rail and in-
jector mounting holes with vinyl tape to prevent dust from
being introduced.
62. REMOVE FUEL PIPE NO.3 (See page 14 −108)
SST 09023 −12700
Page 4616 of 5135

A93406
SST
A09656
A85924
14−168−
ENGINE MECHANICAL CYLINDER HEAD GASKET (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
63. REMOVE INJECTION PIPE SUB −ASSY NO.1
(a) Remove the 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, in order to prevent dust or
foreign objects from being introduced, cover the common
rail with vinyl tape and protect the injector inlet with a vinyl
or plastic bag.
(e) Remove the 2 lower injection pipe clamps from the intake manifold.
64. REMOVE INJECTION PIPE SUB −ASSY NO.2
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
65. REMOVE INJECTION PIPE SUB −ASSY NO.3
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
66. REMOVE INJECTION PIPE SUB −ASSY NO.4
SST 09023 −12700
HINT:
Perform the same procedures as the injection pipe No. 1.
67. REMOVE VACUUM PUMP ASSY (See page 14 −108)
68. REMOVE NOZZLE LEAKAGE PIPE NO.2 (See page 14 −108)
69. REMOVE NOZZLE HOLDER SEAL
(a) Using a screwdriver, pry out the 4 nozzle holder seals.
70. REMOVE CYLINDER HEAD COVER SUB −ASSY
(a) Remove the 10 bolts, cylinder head cover and gasket.