2005 TOYOTA AVENSIS compression ratio

A62186
Paint Mark
A62187
Fix
Tighten
A62188
24 5 3 1
A32124
A6218924 31 14±22
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
65. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the timing chain and camshaft tim-
ing sprockets.
(c) Remove the 2 bolts and chain tensioner.
(d) Fix the camshaft with a spanner and so on, then loosen
the camshaft timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.
(e) Loosen the camshaft bearing cap bolts on No. 2 camshaft
in the order as shown in the illustration in several passes,
and remove the caps.
(f) Remove the camshaft timing gear as shown in the illustra-
tion.
(g) Loosen the camshaft bearing cap bolts on camshaft in the
order as shown in the illustration in several passes, and
remove the caps.

05±420
± DIAGNOSTICSSFI SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE
DETECTED
DTC P0301 CYLINDER 1 MISFIRE DETECTED
DTC P0302 CYLINDER 2 MISFIRE DETECTED
DTC P0303 CYLINDER 3 MISFIRE DETECTED
DTC P0304 CYLINDER 4 MISFIRE DETECTED
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And
when the misfire rate equals to or exceeds the count of indicating that the engine condition has deteriorated,
the CHK ENG is illuminated.
If the misfire rate is high enough and the driving conditions will cause the catalyst to overheat, the CHK ENG
blinks when misfiring occurs.
HINT:

For any particular 200 revolutions of the engine, misfiring which would result in overheating of catalyst
is detected. This cause CHK ENG to blink (1 trip detection logic).

For any particular 1,000 revolutions of engine, misfiring which would result in a deterioration of emis-
sions. This illuminates CHK ENG (2 trip detection logic).
DTC No.DTC Detection ConditionTrouble Area
P0300Misfiring of random cylinders is detected

Open or short in engine wire

Connector connection

Vacuum hose connection

Ignition system

Injector
P0301
P0302
Misfiring of each cylinder is detected

Fuel pressure

Mass air flow meter

Engine coolant temperature sensor

Compression pressure


Valve clearanceP0302
P0303
P0304Misfiring of each cylinder is detected
Valve clearance

Valve timing

PCV hose connection

PCV hose

ECM
HINT:
When codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indi-
cates that the misfires have been detected and recorded at different times.
05CKH±01

A81504
Injector Cross Section DiagramPiston
Solenoid Valve
Nozzle Needle
05±658
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP1238INJECTOR MALFUNCTION
HINT:

For more information on the injector and the common rail system, see page 05±517.

If P1238 is present, use the diagnostic trouble code matrix for fuel sys\
tem, see page 05±517.
CIRCUIT DESCRIPTION
The ECM detects combustion deterioration for specific cylinder.
HINT:

The cylinder that has compensation learned value for INJ VOL varies from other cylinders may be mal-
functioning.

If DTC P0093 (Fuel leaks in high±pressure area) is present simultan\
eously, leakage malfunction of the
cylinder probably be occurred.

If DTC P0200 (Open or short in EDU or injector circuit) is present sim\
ultaneously, there probably be
faulty circuit located between the ECM and the injector including the ED\
U.

If only DTC P1238 (Injector malfunction) is present, probably the injector is \
mechanical malfunction
or insufficient compression (valve clearance, etc) has occurred, not an open o\
r short malfunction of
the ECM, EDU and injector circuit.

Solenoid valve of the injector is the same type of the pressure discharg\
e valve.
05CQ0±01

±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
05±659
AVENSIS REPAIR MANUAL (RM1018E)DTC No.
DTC Detection ConditionMain Trouble AreaRelated Trouble Area
P1238Engine speed variation is large when idling.


Injector

EDU (P0200is set simultaneous-
ly)

Open or short in engine wire
(P0200is set simultaneously)

Connector connection (P0200is
set simultaneously)

Compression pressure

Valve clearance

Valve timing

ECM
HINT:
After confirming DTC P1238, use the hand±held tester to confirm the fuel pressure inside the common rail
in the ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / COMN RAIL PRESSº.
Engine SpeedFuel Pressure (MPa)
IdlingApprox. 30 to 40
Running the engine at 2,500 rpm (No engine load)Approx. 50 to 100
MONITOR DESCRIPTION
P1238 (Injection malfunction, exclude open or short in injector circuit):
This DTC will be set if the engine speed variations between each cylinder is\
large. The ECM monitors
changes in the crankshaft rotation speed using the crankshaft position sensor f\
or detecting poor combus-
tion. Also, it identifies faulty cylinder using the camshaft position sensor. The fluctuation counter increments
when irregular crankshaft rotation speed variation exceeds the threshold at i\
dling. Therefore, either one of
the cylindershas very poor combustion (Rough idle), the ECM sets this DTC.
MONITOR STRATEGY
Required sensorsCrankshaft position sensor
Frequency of operationContinuous
Duration10 min.
CHK ENG operation2 driving cycles
TYPICAL ENABLING CONDITIONS
ItemSpecificationItemMinimumMaximum
EngineAt idling
Engine speed500 rpm±
Engine coolant temperature20 C (68 F)
TYPICAL MALFUNCTION THRESHOLDS
Threshold
The number of irregular changes in the crankshaft rotation speed
HINT:
The number of irregular changes in the crankshaft rotation speed indicat\
es the insufficient combustion cylin-
der.
WIRING DIAGRAM
Refer to DTC P0200 on page 05±604.

05CDX−02
05 −1 0
−
DIAGNOSTICS SFI SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM 1045E)
PROBLEM SYMPTOMS TABLE
When the malfunction is not confirmed in the diagnostic trouble code check and the problem still can not be
confirmed in the basic inspection, proceed to this matrix chart and troubleshoot according to the numbered
order given below.
SymptomSuspected AreaSee page
Engine does not crank (Does not start)
1. Starter
2. Starter relay
3. Park/neutral position switch19 −1
1 9 −1
* 1
No initial combustion (Does not start)
1 . ECM power source circuit
2. Ignition coil assy
3. Fuel pump control circuit
4. Injector circuit05 −236
05 −1 67
05 −24 1
05 −1 36
No complete combustion (Does not start)
1. Ignition coil assy
2. Fuel pump control circuit
3. Injector circuit05 −1 67
05 −24 1
05 −1 36
Difficult to start (Engine cranks normally)
1. Starter signal circuit
2. Ignition coil assy
3. Spark plug
4. Compression
5. Injector circuit
6. Fuel pump control circuit05 −249
05 −1 67
1 8 − 3
1 4 −1
05 −1 36
05 −24 1
Difficult to start with cold engine
1. Starter signal circuit
2. Injector circuit
3. Ignition coil assy
4. Spark plug
5. Fuel pump control circuit05 −249
05 −1 36
05 −1 67
1 8 − 3
05 −24 1
Difficult to start with hot engine
1. Starter signal circuit
2. Injector circuit
3. Ignition coil assy
4. Spark plug
5. Fuel pump control circuit05 −249
05 −1 36
05 −1 67
1 8 − 3
05 −24 1
High engine idle speed (Poor idling)
1. ECM power source circuit
2. Park/neutral position switch
3. Back up power source circuit05 −236
* 1
05 −1 99
Low engine idle speed (Poor idling)
1. Park/neutral position switch
2. Injector circuit
3. Back up power source circuit
4. Fuel pump control circuit* 1
05 −1 36
05 −1 99
05 −24 1
Rough idling (Poor idling)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. Injector circuit
4. Fuel pump control circuit
5. Ignition coil assy
6. Compression
7. Back up power source circuit05 −55
05 −61
05 −1 36
05 −24 1
05 −1 67
1 4 −1
05 −1 99
Hunting (Poor idling)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. ECM power source circuit05 −55
05 −61
05 −236
Hesitation/Poor acceleration (Poor driveability)
1. Mass air flow meter circuit
2. Vacuum sensor circuit
3. Injector circuit
4. Ignition coil assy
5. Fuel pump control circuit05 −55
05 −61
05 −1 36
05 −1 67
05 −24 1
Muffler explosion after fire (Poor driveability)
1. Ignition coil assy
2. Spark plug
3. Injector circuit05 −1 67
1 8 − 3
05 −1 36

05−446
− DIAGNOSTICSECD SYSTEM (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E) DTC No.
DTC Detection ConditionMain Trouble AreaRelated Trouble Area
SExcess or low fuel addition volume from exhaust
fuel addition injector:
When air−fuel ratio deviates from a value estimated
by ECM while the injector adds fuel
(1trip detection logic)SOpen in exhaust temperature
sensor circuit
SA/F sensor
SExhaust gas temperature sensor
SSupply pump assy
SMass air flow meter
SFuelleaksinexhaustfueladdi-
P1386
SLow fuel addition volume from exhaust fuel addition
injector:
When learning value (*3) exceeds standard level
(1trip detection logic)SOpen or short in exhaust fuel
addition injector circuit
SExhaust fuel addition injector
SDPNR catalytic converter (Man-
ifold converter sub−assy)
SFuelleaksinexhaustfueladdi-
tion injector
SMain injector
SCylinder compression pressure
SValve clearance
SValve timing
Airintakesystemhasblockages
SExhaust fuel addition injector nozzle stuck open:
When air−fuel ratio becomes RICHER than standard
level, or exhaust gas temperature reaches higher
than standard level
(1trip detection logic)
SAir intake system has blockages
SAir intake system has leakage
SExhaust system has blockages
SExhaust system has leakage
SEGR system has blockages
SEGR system has leakage
SECM
*3: Correction learning value of the fuel addition volume to raise the DPNR catalyst temperature to a target
range.
HINT:
DTC P2047 (Reductant injector circuit/open [bank1unit1]) will be present if there is an open malfunction in
the exhaust fuel addition injector circuit.

A81504
Injector Cross Section Diagram:Piston
Solenoid Valve
Nozzle Needle
−
DIAGNOSTICS ECD SYSTEM (1CD−FTV)(From September, 2003)
05 −43 1
AVENSIS Supplement (RM1045E)
DTC P 1238 INJECTOR MALFUNCTION
HINT:
S For more information on the injector and the common rail system, see page 05 −255.
S If P1238 is present, refer to the diagnostic trouble codes (DTCs) table for the fuel system on page
05 −255.
CIRCUIT DESCRIPTION
The ECM detects combustion deterioration for a specific cylin-
der.
HINT:
SThe cylinder, which has compensation value for INJ VOL
that varies from other cylinders, may be malfunctioning.
SIf DTC P0093 (Fuel leaks in high −pressure area) is pres-
ent simultaneously, leakage malfunction of the cylinder
probably be occurred.
SIf DTC P0200 (Open or short in EDU or injector circuit) is
present simultaneously, there probably be faulty circuit lo-
cated between the ECM and the injector including the
EDU.
SIf only DTC P1238 (Injector malfunction) is present, prob-
ably injector mechanical malfunction or insufficient com-
pression (valve clearance etc) has occurred, not an open
or short malfunction of the ECM, EDU and injector circuit.
SSolenoid valve of the injector is the same type that of the
pressure discharge valve.
DTC No.DTC Detection ConditionMain Trouble AreaRelated Trouble Area
P1238Engine speed fluctuation is large when idling
(2 trip detection logic)
S Injector
S EDU (P0200 is set simultaneous-
ly)
S Open or short in engine wire har-
ness (P0200 is set simultaneous-
ly)
S Connector connection (P0200 is
set simultaneously)
S Compression pressure
S Valve clearance
SValve timing
S ECM
HINT:
After confirming DTC P1238, check the internal fuel pressure in ”DIAGNOSIS / OBD/MOBD / DATA LIST
/ ALL / COMN RAIL” using the hand −held tester.
Reference:
Engine SpeedFuel Pressure (MPa)
IdlingApproximately 30 to 40
2,500 rpm (No engine load)Approximately 50 to 100
05CQ0 −05

SST
A09620
A85427
TDC Mark
Dot Mark90_
A09624
A09625
14−154
− ENGINE MECHANICALCAMSHAFT (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
45. INSTALL CAMSHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the camshaft oil seal retainer edge.
SST 09223−46011
(b) Apply multipurpose grease to a new oil seal lip.
NOTICE:
Keep the lip free of foreign object.
46. 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.
47. INSTALL CAMSHAFT
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while being installed. If the
camshaft is not kept level, the cylinder head or camshaft
may be damaged. To avoid this, the following procedures
should be carried out.
(a) Place the camshaft carrier on the cylinder head.
(b) Install the camshaft.
(c) Apply engine oil to the cam and gear of the camshaft, and
the journal of the camshaft carrier.
(d) Place the intake camshaft on the camshaft carrier so that
the No. 3 and No. 4 of the cylinder cam lobes face down-
ward as shown in the illustration.