10–66 ENGINE CONTROL SYSTEM
–
ACCELERATOR PEDAL ASSY (1AZ–FSE/1CD–FTV)
ACCELERATOR PEDAL ASSY (1AZ–FSE/1CD–FTV) 100FM–02
REPLACEMENT 1. (a) (b)
REMOVE ACCELERATOR PEDAL Using a clip remover, remove the clip. Open the floor carpet.
(c) (d)
Disconnect the accelerator position sensor connector. Remove the 2 bolts, and then remove the accelerator pedal.
A78489
A78490
2.
INSTALL ACCELERATOR PEDAL Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
AVENSIS REPAIR MANUAL (RM1018E)
10–63 ENGINE CONTROL SYSTEM
–
CAMSHAFT POSITION SENSOR (1CD–FTV)
CAMSHAFT POSITION SENSOR (1CD–FTV) 100FP–01
REPLACEMENT 1. (a)
SEPARATE RETURN TUBE SUB–ASSY Remove the bolt and separate the return tube sub–assy.
2. (a) (b)
REMOVE CAMSHAFT POSITION SENSOR Remove the bolt and disconnect the wire harness. Disconnect the connector, remove the bolt and the camshaft position sensor.
A79139
A79141
3.
4.
INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 Nm (90 kgfcm, 79 in.lbf) for camshaft position sensor 5.0 Nm (51 kgfcm, 44 in.lbf) for wire harness INSTALL RETURN TUBE SUB–ASSY Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
AVENSIS REPAIR MANUAL (RM1018E)
10–64 ENGINE CONTROL SYSTEM
–
CRANKSHAFT POSITION SENSOR (1CD–FTV)
CRANKSHAFT POSITION SENSOR (1CD–FTV) 100FQ–01
REPLACEMENT 1.
REMOVE ENGINE UNDER COVER RH 2. (a)
REMOVE CRANKSHAFT POSITION SENSOR Disconnect the connector, remove the bolt and the crankshaft position sensor.
A79142
3.
INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 Nm (90 kgfcm, 78 in.lbf)
AVENSIS REPAIR MANUAL (RM1018E)
10–56 ENGINE CONTROL SYSTEM
–
ECD SYSTEM (1CD–FTV) 100F0–02
INSPECTION
1. (a)
Air VG
+B E2 E2G THA
5 4 3 2 1
(b) 30 20
RESISTANCE k
10 5 3 2
INSPECT MASS AIR FLOW METER Output voltage inspection. (1) Apply battery voltage across terminals 3 (+B) and 4 (E2G) (2) Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (–) tester probe to terminal E2G. (3) Blow air into the air flow meter, and check that the voltage fluctuates. Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals 2 (THA) and 1 (E2). Resistance: –20C (–4F) 12.5 to 16.9 k 20C (68F) 2.19 to 2.67 k 60C (140F) 0.50 to 0.68 k
1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (80) (104)(140) (176) (212) TEMPERATUREC(F)
A56275
2. (a)
INSPECT INTAKE SHUTTER ASSY Resistance inspection (Throttle control motor) (1) Using an ohmmeter, measure the resistance between terminals. Resistance:
A31135
AVENSIS REPAIR MANUAL (RM1018E)
Terminals
Temperature
Resistance
2 – 1, 3
at 20C (68F)
18 to 22 k
5 – 4, 6
at 20C (68F)
18 to 22 k
10–57 ENGINE CONTROL SYSTEM
30 20 Resistance k
ECD SYSTEM (1CD–FTV)
3.
Ohmmeter
10 5
–
Acceptable
3 2 1
INSPECT DIESEL ENGINE ENGINE COOLANT TEMPERATURE SENSOR (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between each terminal. Resistance: Approx. 20C (68F) 2.32 to 2.59 k Approx. 80C (176F) 0.310 to 0.326 k NOTICE: In case of checking the water temperature sensor in the water, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
0.5 0.3 0.2 0.1 –20
0
20 40 60 80 100
(–4) (32) (68) (104) (140) (176) (212)
Temperature C (F)
THF
Z17274
E2
4. (a)
INSPECT INJECTION OR SUPPLY PUMP ASSY Resistance inspection. (Fuel temperature sensor) (1) Using an ohmmeter, measure the resistance between each terminal. Resistance: Approx. 20C (68F) 2.21 to 2.69 k Approx. 80C (176F) 0.287 to 0.349 k
5.
INSPECT DIESEL TURBO INLET AIR TENPERATURE SENSOR Resistance inspection. (1) Using an ohmmeter, measure the resistance between each terminal. Resistance: Approx. 20C (68F) 2.21 to 2.65 k
A30331
(a) 30 20
Resistance k
10 0.5 0.3 0.2 0.1
F14741
–20 20 40 60 80 100 (–4) (32) (68) (104) (140) (176) (212)
Temperature C (F) A56276
AVENSIS REPAIR MANUAL (RM1018E)
10–58 ENGINE CONTROL SYSTEM
NE–
NE+
INSPECT CRANKSHAFT POSITION SENSOR Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals. Resistance: at cold 1630 to 2740 at hot 2065 to 3225 NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the sensor itself. ”Cold” is from –10C (14F) to 50C (122F) and ”Hot” is from 50C (122F) to 100C (212F).
7. (a)
NE–
A57060
INSPECT CAMSHAFT POSITION SENSOR Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminal. Resistance: at cold 1630 to 2740 at hot 2065 to 3225 NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the sensor itself. ”Cold” is from –10C (14F) to 50C (122F) and ”Hot” is from 50C (122F) to 100C (212F).
8. (a)
B16200
AVENSIS REPAIR MANUAL (RM1018E)
ECD SYSTEM (1CD–FTV)
6. (a)
A56277
NE+
–
(b)
INSPECT EDU RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–59 ENGINE CONTROL SYSTEM
9. (a)
B16200
(b)
10. (a)
–
ECD SYSTEM (1CD–FTV)
INSPECT EFI MAIN RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
INSPECT ACCELERATOR PEDAL ASSY Inspect the accel position sensor. (1) Using an ohmmeter, measure the resistance between each terminal. Resistance:
RHD:
A31135
Between terminal
Resistance
5 (VPA1) – 1 (EP1)
5.0 kW or less
2 (VPA2) – 3 (EP2)
5.0 kW or less
4 (VCP1) – 1 (EP1)
1.5 to 6.0 kW
6 (VCP2) – 3 (EP2)
1.5 to 6.0 kW
Between terminal
Resistance
3 (VPA1) – 4 (EP1)
5.0 kW or less
6 (VPA2) – 5 (EP2)
5.0 kW or less
2 (VCP1) – 4 (EP1)
1.5 to 6.0 kW
1 (VCP2) – 5 (EP2)
1.5 to 6.0 kW
LHD:
AVENSIS REPAIR MANUAL (RM1018E)
10–54 ENGINE CONTROL SYSTEM
–
ECD SYSTEM (1CD–FTV)
ECD SYSTEM (1CD–FTV) 100EZ–02
ON–VEHICLE INSPECTION 1. (a)
Air
A75903
(b)
VG
EVG A53763
2. (a)
INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation (1) Connect the hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the CURRENT DATA shown the standard value. If operation is not as specified, check the MAF meter (See page 10–56), wiring and ECM.
If you have no hand–held tester: Inspect for operation (1) Turn the ignition switch ON. (2) Connect the positive tester probe of the voltmeter to the terminal VG of the ECM. and the negative tester probe of the voltmeter to the terminal EVG of the ECM. (3) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, check the MAF meter (See page 10–56), wiring and ECM.
INSPECT INTAKE SHUTTER Inspect the throttle control motor for operating sound. (1) Turn the ignition switch ON. (2) When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See page 10–56), wiring and ECM. (b) Inspect the throttle position sensor. (1) Connect the hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) When turning the accelerator pedal position sensor lever to the full–open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See page 10–56), wiring and ECM. If you have no hand–held tester, measure voltage between terminals (LU+A – LU–A, LU+B – LU–B) of the ECM connector (See page 05–549). AVENSIS REPAIR MANUAL (RM1018E)
10–55 ENGINE CONTROL SYSTEM
(c)
–
ECD SYSTEM (1CD–FTV)
Inspect the air assist system. (1) Start the engine and check that the CHK ENG does not light up. (2) Allow the engine to warm up to normal operating temperature. (3) Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 800 50 rpm NOTICE: Perform inspection under condition without electrical load. (d) After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 3. INSPECT ACCELERATOR PEDAL POSITION SENSOR (a) Connect the hand–held tester to the DLC3. (b) Turn the ignition switch ON. (c) Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value. Accelerator pedal released: 0.5 to 1.1 V Accelerator pedal depress: 2.6 to 4.5 V (d) Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value. Accelerator pedal released: 1.2 to 2.0 V Accelerator pedal depress: 3.4 to 5.3 V If you have no hand–held tester, measure voltage between terminals (VPA1 – EP1, VPA2 – EP2) of the ECM connector (See page 05–549).
AVENSIS REPAIR MANUAL (RM1018E)
10–65 ENGINE CONTROL SYSTEM
–
ECM
ECM 100FR–01
REPLACEMENT HINT: 1CD–FTV Engine Type: Each injector assembly has a characteristic fuel injecting behavior. The ECM stores compensation codes which are used to optimize fuel injection for the injectors. When replacing the ECM, the compensation codes must be set to the new ECM. 1. REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71–11) 2. (a) (b) (c) (d) (e) A79186
3. 4. 5.
(f)
REMOVE ECM Disconnect the 4 ECM connectors (1ZZ–FE, 3ZZ–FE, 1AZ–FE, 1CD–FTV). Disconnect the 5 ECM connectors (1AZ–FSE). Disconnect the wire harness clamp. Remove the bolt and screw, then remove the ECM. Remove the 2 screws and the ECM bracket No. 1 from the ECM. Remove the 2 screws and the ECM bracket No. 2 from the ECM.
INSTALL ECM Torque: 5.5 Nm (56 kgfcm, 49 in.lbf) INSTALL GLOVE COMPARTMENT DOOR ASSY (See page 71–11) REGISTRATION OF INJECTOR COMPENSATION CODE (1CD–FTV ENGINE TYPE) (See page 05–528)
AVENSIS REPAIR MANUAL (RM1018E)
10–60 ENGINE CONTROL SYSTEM
–
INTAKE SHUTTER ASSY (1CD–FTV)
INTAKE SHUTTER ASSY (1CD–FTV) 100FN–01
COMPONENTS Clip Retainer
8.0 (82, 71 in.lbf)
Engine Cover No. 1 Radiator Support Opening Cover
30 to 40 (31 to 41 , 27 to 35 in.lbf) 5.0 (51, 44 in.lbf)
Battery
Battery Tray
Gasket Intake Shutter Assy 21 (214, 15)
Air Hose No. 4
25 (255,18 )
Air Tube No. 2
25 (255, 18)
N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A79433
AVENSIS REPAIR MANUAL (RM1018E)
10–61 ENGINE CONTROL SYSTEM
–
INTAKE SHUTTER ASSY (1CD–FTV) 100FO–01
Removal & Installation and Disassembly & Reassembly 1. 2. (a) 3.
REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover. REMOVE BATTERY
4. (a) (b) (c)
REMOVE AIR HOSE NO.4 Loosen the 2 hose clamps. Remove the 2 bolts and separate the air tube No. 2. Remove the air hose No. 4.
5. (a) (b)
REMOVE INTAKE SHUTTER ASSY Disconnect the 2 connectors. Remove the 3 nuts, then remove the intake shutter and the gasket.
A80092
B08171
6. (a)
INSTALL INTAKE SHUTTER ASSY Install a new gasket and the intake shutter Torque: 21 Nm (214 kgfcm, 15 ftlbf) 7. (a) (b)
(c)
2 to 7 mm
0 to 4 mm
A64328
AVENSIS REPAIR MANUAL (RM1018E)
with the 3 nuts. INSTALL AIR HOSE NO.4 Install the air hose No. 4 to the air tube No. 2. Install the air tube No. 2 with the 2 bolts. Torque: 25 Nm (255 kgfcm, 18 ftlbf)
Install the air hose and hose clamp as shown in the illustration.
10–62 ENGINE CONTROL SYSTEM
(d)
Front
–
INTAKE SHUTTER ASSY (1CD–FTV)
Tighten the hose clamp as shown in the illustration. Torque: 6.0 Nm (61 kgfcm, 53 in.lbf)
90 Clamp Bolt
A64007
8. (a) 9.
INSTALL ENGINE COVER NO.1 Install the engine cover with the 5 nuts. Torque: 8.0 Nm (82 kgfcm, 71 in.lbf) INSTALL BATTERY Torque: 5.0 Nm (51 kgfcm, 44 in.lbf) for bolt 3.0 to 4.0 Nm (31 to 41 kgfcm, 27 to 35 in.lbf) for nut
AVENSIS REPAIR MANUAL (RM1018E)
10–30 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE)
KNOCK SENSOR (1AZ–FE) 100FK–01
COMPONENTS Clip
x2
Engine Room Cover Side
x4 Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.lbf)
Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose
VSV Connector
Mass Air Flow Meter Connector Air Cleaner Cap Sub–assy
N·m (kgf·cm, ft·lbf) : Specified torque
Fuel Vapor Feed Hose No. 2 A77870
AVENSIS REPAIR MANUAL (RM1018E)
10–31 ENGINE CONTROL SYSTEM
Accelerator Control Cable Assy 13 (129, 9)
–
KNOCK SENSOR (1AZ–FE)
ISC Valve Connector
30 (306, 22)
Throttle Position Sensor Connector
Fuel Pipe Support Throttle Body Assy Fuel Tube Sub–assy
Throttle Body Gasket
Water By–pass Hose
Water By–pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78452
10–32 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE)
Fuel Injector Connector
20 (204, 15)
Fuel Delivery Pipe Sub–assy
EFI Fuel Pipe Clamp
Fuel Tube Sub–assy
Delivery Pipe No. 1 Spacer Injector Vibration Insulator
Ventilation Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78453
10–33 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE)
Charcoal Canister Outlet Hose No. 1 5.0 (51, 44 in.lbf)
LHD Steering Position Type, Leaded Gasoline: Variable Resister Variable Resister Connector Intake Manifold to Head Gasket No. 1
Fuel Hose
Charcoal Canister Assy
x5
30 (306, 22)
Intake Manifold
Heater Inlet Water Hose
Knock Sensor 20 (204, 15)
Knock Sensor Connector
Intake Manifold Insulator No. 1 N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A77916
10–34 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE) 100FL–01
REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) ENGINE COOLANT (See page 16–19) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–26) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–26) SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10–26) REMOVE THROTTLE BODY ASSY (See page 10–26) DISCONNECT FUEL TUBE SUB–ASSY (See page 11–26) SST 09268–21010 REMOVE FUEL DELIVERY PIPE SUB–ASSY (See page 11–26)
11. (a) (b)
REMOVE VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Disconnect the variable resistor connector. Remove the bolt, and then remove the variable resistor.
12. (a) (b) (c)
REMOVE CHARCOAL CANISTER ASSY Disconnect the charcoal canister outlet hose No. 1. Disconnect the fuel hose. Pull up and remove the charcoal canister.
13.
DISCONNECT HEATER INLET WATER HOSE
A77917
(b) (a)
A77918
A77919
AVENSIS REPAIR MANUAL (RM1018E)
10–35 ENGINE CONTROL SYSTEM
LHD:
RHD:
–
KNOCK SENSOR (1AZ–FE)
14. (a)
REMOVE INTAKE MANIFOLD Disconnect the union to connector tube hose.
(b) (c) (d)
Remove the wire harness clamp. Remove the 5 bolts and 2 nuts, and then remove the intake manifold. Remove the gasket from the intake manifold.
15.
REMOVE INTAKE MANIFOLD INSULATOR NO.1
16. (a) (b)
REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut, and then remove the knock sensor.
17. (a)
INSTALL KNOCK SENSOR Install the knock sensor with the nut as shown in the illustration. Torque: 20 Nm (204 kgfcm, 15 ftlbf) Connect the knock sensor connector.
A77920
(b)
A77921
A77922
A78435
Upper 10 Engine Front 10
A78436
AVENSIS REPAIR MANUAL (RM1018E)
(b)
10–36 ENGINE CONTROL SYSTEM
18. 19. (a) (b) (c) (d) 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
–
KNOCK SENSOR (1AZ–FE)
INSTALL INTAKE MANIFOLD INSULATOR NO.1 INSTALL INTAKE MANIFOLD Install a new gasket to the intake manifold. Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 Nm (306 kgfcm, 22 ftlbf) Install the wire harness clamp. Connect the union to connector tube hose. CONNECT HEATER INLET WATER HOSE INSTALL CHARCOAL CANISTER ASSY INSTALL VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Torque: 5.0 Nm (51 kgfcm, 44 in.lbf) INSTALL FUEL DELIVERY PIPE SUB–ASSY (See page 11–26) CONNECT FUEL TUBE SUB–ASSY (See page 11–26) INSTALL THROTTLE BODY ASSY (See page 10–26) INSTALL ACCELERATOR CONTROL CABLE ASSY (See page 10–26) INSTALL AIR CLEANER CAP SUB–ASSY ADD ENGINE COOLANT (See page 16–19) CHECK FOR ENGINE COOLANT LEAKS (See page 16–13) CHECK FOR FUEL LEAKS (See page 11–19) INSTALL ENGINE COVER SUB–ASSY NO.1 (See page 10–26) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)
10–30 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE)
KNOCK SENSOR (1AZ–FE) 100FK–01
COMPONENTS Clip
x2
Engine Room Cover Side
x4 Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.lbf)
Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose
VSV Connector
Mass Air Flow Meter Connector Air Cleaner Cap Sub–assy
N·m (kgf·cm, ft·lbf) : Specified torque
Fuel Vapor Feed Hose No. 2 A77870
AVENSIS REPAIR MANUAL (RM1018E)
10–31 ENGINE CONTROL SYSTEM
Accelerator Control Cable Assy 13 (129, 9)
–
KNOCK SENSOR (1AZ–FE)
ISC Valve Connector
30 (306, 22)
Throttle Position Sensor Connector
Fuel Pipe Support Throttle Body Assy Fuel Tube Sub–assy
Throttle Body Gasket
Water By–pass Hose
Water By–pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78452
10–32 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE)
Fuel Injector Connector
20 (204, 15)
Fuel Delivery Pipe Sub–assy
EFI Fuel Pipe Clamp
Fuel Tube Sub–assy
Delivery Pipe No. 1 Spacer Injector Vibration Insulator
Ventilation Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78453
10–33 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE)
Charcoal Canister Outlet Hose No. 1 5.0 (51, 44 in.lbf)
LHD Steering Position Type, Leaded Gasoline: Variable Resister Variable Resister Connector Intake Manifold to Head Gasket No. 1
Fuel Hose
Charcoal Canister Assy
x5
30 (306, 22)
Intake Manifold
Heater Inlet Water Hose
Knock Sensor 20 (204, 15)
Knock Sensor Connector
Intake Manifold Insulator No. 1 N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A77916
10–34 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FE) 100FL–01
REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11–15) REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) ENGINE COOLANT (See page 16–19) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–26) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–26) SEPARATE ACCELERATOR CONTROL CABLE ASSY (See page 10–26) REMOVE THROTTLE BODY ASSY (See page 10–26) DISCONNECT FUEL TUBE SUB–ASSY (See page 11–26) SST 09268–21010 REMOVE FUEL DELIVERY PIPE SUB–ASSY (See page 11–26)
11. (a) (b)
REMOVE VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Disconnect the variable resistor connector. Remove the bolt, and then remove the variable resistor.
12. (a) (b) (c)
REMOVE CHARCOAL CANISTER ASSY Disconnect the charcoal canister outlet hose No. 1. Disconnect the fuel hose. Pull up and remove the charcoal canister.
13.
DISCONNECT HEATER INLET WATER HOSE
A77917
(b) (a)
A77918
A77919
AVENSIS REPAIR MANUAL (RM1018E)
10–35 ENGINE CONTROL SYSTEM
LHD:
RHD:
–
KNOCK SENSOR (1AZ–FE)
14. (a)
REMOVE INTAKE MANIFOLD Disconnect the union to connector tube hose.
(b) (c) (d)
Remove the wire harness clamp. Remove the 5 bolts and 2 nuts, and then remove the intake manifold. Remove the gasket from the intake manifold.
15.
REMOVE INTAKE MANIFOLD INSULATOR NO.1
16. (a) (b)
REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut, and then remove the knock sensor.
17. (a)
INSTALL KNOCK SENSOR Install the knock sensor with the nut as shown in the illustration. Torque: 20 Nm (204 kgfcm, 15 ftlbf) Connect the knock sensor connector.
A77920
(b)
A77921
A77922
A78435
Upper 10 Engine Front 10
A78436
AVENSIS REPAIR MANUAL (RM1018E)
(b)
10–36 ENGINE CONTROL SYSTEM
18. 19. (a) (b) (c) (d) 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
–
KNOCK SENSOR (1AZ–FE)
INSTALL INTAKE MANIFOLD INSULATOR NO.1 INSTALL INTAKE MANIFOLD Install a new gasket to the intake manifold. Install the intake manifold with the 5 bolts and 2 nuts. Torque: 30 Nm (306 kgfcm, 22 ftlbf) Install the wire harness clamp. Connect the union to connector tube hose. CONNECT HEATER INLET WATER HOSE INSTALL CHARCOAL CANISTER ASSY INSTALL VARIABLE RESISTOR (LHD STEERING POSITION TYPE, LEADED GASOLINE) Torque: 5.0 Nm (51 kgfcm, 44 in.lbf) INSTALL FUEL DELIVERY PIPE SUB–ASSY (See page 11–26) CONNECT FUEL TUBE SUB–ASSY (See page 11–26) INSTALL THROTTLE BODY ASSY (See page 10–26) INSTALL ACCELERATOR CONTROL CABLE ASSY (See page 10–26) INSTALL AIR CLEANER CAP SUB–ASSY ADD ENGINE COOLANT (See page 16–19) CHECK FOR ENGINE COOLANT LEAKS (See page 16–13) CHECK FOR FUEL LEAKS (See page 11–19) INSTALL ENGINE COVER SUB–ASSY NO.1 (See page 10–26) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)
10–47 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FSE)
KNOCK SENSOR (1AZ–FSE) 100F9–01
COMPONENTS Clip
x2
Engine Room Cover Side
x4
Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.lbf)
Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose 1.5 (15, 13 in.lbf)
VSV Connector
Mass Air Flow Meter Connector
Air Cleaner Cap Sub–assy
N·m (kgf·cm, ft·lbf) : Specified torque A78507
AVENSIS REPAIR MANUAL (RM1018E)
10–48 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FSE)
Throttle Motor Connector
Throttle Body Assy x4
9.0 (90, 80 in.lbf)
Throttle Body Gasket Water By–pass Hose No. 1
Water By–pass Hose No. 2
x4
Throttle Body Bracket
21 (210, 15)
Ground Terminal
8.4 (86, 74 in.lbf)
Wire Harness Protector
8.4 (86, 74 in.lbf)
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78508
10–49 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FSE)
Fuel Tube Sub–assy Gasket
Fuel Pipe Clamp
Gasket
25 (255, 18) 33 (331, 24)
Fuel Pump Insulator
Fuel Pump Assy
Fuel Pressure Pulsation Damper Assy
30 (306, 22)
Fuel pipe Sub–assy No. 1 9.0 (92, 80 in.lbf)
Fuel Hose
Fuel Injector Back–up Ring No. 1 Fuel Injector Back–up Ring No. 2 O–ring Fuel Injector Back–up Ring No. 3
38 (388, 28)
Engine Cover Bracket
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A79577
10–50 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FSE)
30 (306, 22)
Union to Connector Tube Hose 30 (306, 22)
Vacuum Hose
Intake Manifold Insulator No. 1
Intake Manifold
x2 30 (306, 22)
Gasket Intake Air Control Valve Assy Gasket 9.5 (97, 84 in.lbf)
9.8 (100, 7)
Intake Manifold Insulator No. 2 21 (210, 15)
Surge Tank Stay No. 1
38 (388, 28)
Engine Cover Bracket
Charcoal Canister Assy
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A79597
10–51 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FSE)
Knock Sensor
20 (204, 15)
N·m (kgf·cm, ft·lbf) : Specified torque A79833
AVENSIS REPAIR MANUAL (RM1018E)
10–52 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1AZ–FSE) 100FA–01
REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
DISCHARGE FUEL SYSTEM PRESSURE (See page 11–30) REMOVE RADIATOR SUPPORT OPENING COVER (See page 18–16) REMOVE ENGINE ROOM COVER SIDE (See page 18–17) REMOVE ENGINE COVER SUB–ASSY NO.1 (See page 10–44) DRAIN ENGINE COOLANT (See page 16–31) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–44) REMOVE THROTTLE BODY ASSY (See page 10–44) REMOVE CHARCOAL CANISTER ASSY REMOVE ENGINE COVER BRACKET (See page 11–52) REMOVE FUEL PUMP ASSY (See page 11–52) REMOVE INTAKE MANIFOLD (See page 11–42) REMOVE SURGE TANK STAY NO.1 (See page 11–42) REMOVE INTAKE MANIFOLD INSULATOR NO.2 (See page 11–42) 14. (a)
REMOVE KNOCK SENSOR Remove the nut and the knock sensor.
15. (a)
INSTALL KNOCK SENSOR Install the knock sensor with the nut as shown in the illustration. Torque: 20 Nm (204 kgfcm, 15 ftlbf)
A79596
Upper 10 Engine Front 10 A78436
16. 17. 18. 19. 20. (a) 21. 22. 23. 24. 25. 26. 27.
INSTALL INTAKE MANIFOLD INSULATOR NO.2 (See page 11–42) INSTALL SURGE TANK STAY NO.1 (See page 11–42) INSTALL INTAKE MANIFOLD (See page 11–42) INSTALL FUEL PUMP ASSY (See page 11–52) INSTALL ENGINE COVER BRACKET Install the engine cover bracket and the bolt. Torque: 38 Nm (388 kgfcm, 28 ftlbf) INSTALL CHARCOAL CANISTER ASSY INSTALL THROTTLE BODY ASSY (See page 10–44) INSTALL AIR CLEANER CAP SUB–ASSY (See page 10–44) ADD ENGINE COOLANT (See page 16–31) CHECK FOR ENGINE COOLANT LEAKS (See page 16–25) CHECK FOR FUEL LEAKS INSTALL ENGINE COVER SUB–ASSY NO.1 Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
AVENSIS REPAIR MANUAL (RM1018E)
10–53 ENGINE CONTROL SYSTEM
28. 29.
–
KNOCK SENSOR (1AZ–FSE)
INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)
10–17 ENGINE CONTROL SYSTEM
–
KNOCK SENSOR (1ZZ–FE/3ZZ–FE)
KNOCK SENSOR (1ZZ–FE/3ZZ–FE) 100FF–01
REPLACEMENT 1. (a)
REMOVE ENGINE UNDER COVER SUB–ASSY NO.1 Remove the 5 clips, 2 screws and bolt, and then remove the engine under cover.
2. (a) (b)
REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Remove the nut, and then remove the knock sensor.
3. (a)
INSTALL KNOCK SENSOR Install the knock sensor with the nut as shown in the illustration. Torque: 20 Nm (204 kgfcm, 15 ftlbf) Connect the knock sensor connector.
A78505
A78502
Upper
(b) 30
30 A78506
4.
INSTALL ENGINE UNDER COVER SUB–ASSY NO.1
AVENSIS REPAIR MANUAL (RM1018E)
10–20 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FE) 100G7–02
INSPECTION
1. (a)
Air E2
VG +B THA E2G
5 4 3 2 1
(b) 30 20
RESISTANCE k
10
INSPECT MASS AIR FLOW METER Output voltage inspection. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (–) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals 4 (THA) and 5 (E2). Resistance:
5
Terminals
Resistance
Temperature
3 2
THA – E2
13.6 to 18.4 k
–20 C (–4 F)
THA – E2
2.21 to 2.69 k
20 C (68 F)
1
THA – E2
0.49 to 0.67 k
60 C (140 F)
2.
0.5 0.3 0.2
(a)
0.1 –20 0 20 40 60 80 100 (–4) (32) (80) (104)(140) (176) (212) TEMPERATUREC(F)
1
A50378
(b)
2
Valve
A50377
B09641
AVENSIS REPAIR MANUAL (RM1018E)
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9 to 7.9 at 20 C (68 F)
Movement inspection. (1) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm the valve does not adhere. HINT: Bad returning of the valve by entrance of foreign objects causes subtle pressure leak to the advanced direction. Then, DTC can be detected. 3. INSPECT THROTTLE BODY ASSY (a) Check throttle body. (1) Check that throttle valve shaft is not rickety. (2) Check that each port is not stopped up. (3) Check that throttle valve opens and closes smoothly. (4) Check that there is no clearance between the throttle stop screw and throttle lever when the closed throttle position.
10–21 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FE)
(b) Adjust the throttle stop screw. NOTICE: The throttle stop screw adjusting is very, so adjust it only when the adjusting is really needed. (1) Loosen the locknut and loosen the screw until it detaches the lever. (2) Confirm that the throttle vale is fully closed. (3) After the screw touches the lever, tighten it by 1/4 revolution additionally and tighten the lock nut. (4) Seal the lock nut with yellow paint. (5) Check that the throttle position sensor operates normally.
4. (a)
VTA
E2
VC A35493
INSPECT THROTTLE POSITION SENSOR Resistance inspection. (1) Disconnect the throttle position sensor connector. (2) Using an ohmmeter, measure the resistance between terminals VC and E2. Resistance: 2.5 to 5.0 k (3) Check the change of resistance between terminals VTA and E2. Change of resistance: The resistance value increases in proportion to the throttle lever opening value.
HINT: Throttle valve
AVENSIS REPAIR MANUAL (RM1018E)
Resistance
Fully close
0.2 to 5.7 k
Fully open
2.0 to 10.2 k
10–22 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FE)
RESISTANCE kW
5.
INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between each terminal. Resistance: Approx. 20C (68F) 2.32 to 2.59kW Approx. 80C (176F) 0.310 to 0.326kW NOTICE: In case of checking the water temperature sensor in the water, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
30 20 10 5 3 2 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (80) (104) (140) (176) (212) TEMPERATUREC(F) A50371
6. (a)
Ohmmeter
INSPECT KNOCK SENSOR Using an ohmmeter, measure the resistance between terminals. Resistance: 120 to 280 kW at 20C (68F)
HINT: If the resistance is not specified, replace the sensor.
A65174
7. (a)
E34090
AVENSIS REPAIR MANUAL (RM1018E)
(b)
INSPECT EFI RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–23 ENGINE CONTROL SYSTEM
8. (a)
E34090
AVENSIS REPAIR MANUAL (RM1018E)
(b)
–
SFI SYSTEM (1AZ–FE)
INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–18 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FE)
SFI SYSTEM (1AZ–FE) 100G6–02
ON–VEHICLE INSPECTION 1. (a)
Air
A75903
INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation (1) Connect the hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the ”DIAGNOSIS / OBD/ MOBD / DATA LIST / ALL” shown the standard value. If operation is not as specified, check the MAF meter (See page 10–20), wiring and ECM.
(b)
VG
EVG A79035
If you have no hand–held tester: Inspect for operation (1) Turn the ignition switch ON. (2) Connect the positive tester probe of the voltmeter to the terminal VG of the ECM. and the negative tester probe of the voltmeter to the terminal EVG of the ECM. (3) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, check the MAF meter (See page 10–20), wiring and ECM.
2.
PSW
(a)
E2 A79035
AVENSIS REPAIR MANUAL (RM1018E)
INSPECT POWER STEERING OIL PRESSURE SENSOR Using a voltmeter, measure the voltage between terminals PSW and E2. Voltage: Condition
Voltage (V)
Not spin the steering wheel at engine idling
9 to 14
Spin the steering wheel at engine idling
0 to 3
10–19 ENGINE CONTROL SYSTEM
Close
Open
Valve
Valve B09650
AVENSIS REPAIR MANUAL (RM1018E)
–
SFI SYSTEM (1AZ–FE)
3. INSPECT IDLE AIR CONTROL VALVE NOTICE: It is impossible to check the resister value and the operation of ISCV by itself, because the ISCV has an IC circuit inside it, which transforms the duty signal from the ECM to the derive signal. After checking, erase the DTC. Clear the DTC after inspection. HINT: When the ISCV system has malfunctions except for its adherence, DTC P0511 is detected. (a) Operation inspection. (1) Connect the ISC valve connector to the ISC valve. (2) Check the ISC valve movement when the ignition switch is turned ON. Movement: Half open fully close fully open half open HINT: ISC valve moves within 0.5 second.
10–39 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FSE) 100G9–02
INSPECTION
1. (a)
Air E2
VG +B THA E2G
5 4 3 2 1
(b) 30 20
RESISTANCE k
10
INSPECT MASS AIR FLOW METER Output voltage inspection. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Using a voltmeter, connect the positive (+) tester probe to terminal 3 (VG), and negative (–) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage fluctuates. Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals 4 (THA) and 5 (E2). Resistance:
5
Terminals
Resistance
Temperature
3 2
THA – E2
13.6 to 18.4 k
–20 C (–4 F)
THA – E2
2.21 to 2.69 k
20 C (68 F)
1
THA – E2
0.49 to 0.67 k
60 C (140 F)
2.
0.5 0.3 0.2
(a)
0.1 –20 0 20 40 60 80 100 (–4) (32) (80) (104)(140) (176) (212) TEMPERATUREC(F)
1
A50378
(b)
2
Valve
A50377
M+
M– A59778
AVENSIS REPAIR MANUAL (RM1018E)
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY Resistance inspection. (1) Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9 to 7.9 at 20 C (68 F)
Movement inspection. (1) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm the valve does not adhere. HINT: Bad returning of the valve by entrance of foreign objects causes subtle pressure leak to the advanced direction. Then, DTC can be detected. 3. INSPECT THROTTLE BODY ASSY (a) Using an ohmmeter, measure the resistance between the terminals. Resistance: Terminal No.
Resistance
2 (M+) – 1 (M–)
0.3 to 100 at 20 C (68 F)
10–40 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FSE)
RESISTANCE kW
4.
INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between each terminal. Resistance: Approx. 20C (68F) 2.32 to 2.59kW Approx. 80C (176F) 0.310 to 0.326kW NOTICE: In case of checking the water temperature sensor in the water, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
30 20 10 5 3 2 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (80) (104) (140) (176) (212) TEMPERATUREC(F) A50371
5. (a)
Ohmmeter
INSPECT KNOCK SENSOR Using an ohmmeter, measure the resistance between terminals. Resistance: 120 to 280 kW at 20C (68F)
HINT: If the resistance is not specified, replace the sensor.
A65174
6. (a)
E34090
AVENSIS REPAIR MANUAL (RM1018E)
(b)
INSPECT EFI RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–41 ENGINE CONTROL SYSTEM
7. (a)
E34090
AVENSIS REPAIR MANUAL (RM1018E)
(b)
–
SFI SYSTEM (1AZ–FSE)
INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–37 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1AZ–FSE)
SFI SYSTEM (1AZ–FSE) 100G8–02
ON–VEHICLE INSPECTION 1. (a)
Air
A75903
INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation (1) Connect the hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the CURRENT DATA shown the standard value. If operation is not as specified, check the MAF meter (See page 10–39), wiring and ECM.
(b) EVG
VG A53763
AVENSIS REPAIR MANUAL (RM1018E)
If you have no hand–held tester: Inspect for operation (1) Turn the ignition switch ON. (2) Connect the positive tester probe of the voltmeter to the terminal VG of the ECM. and the negative tester probe of the voltmeter to the terminal EVG of the ECM. (3) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, check the MAF meter (See page 10–39), wiring and ECM.
10–38 ENGINE CONTROL SYSTEM
E2
2.
PSW
(a)
–
SFI SYSTEM (1AZ–FSE)
INSPECT POWER STEERING OIL PRESSURE SENSOR Using a voltmeter, measure the voltage between terminals PSW and E2. Voltage: Condition
Voltage (V)
Not spin the steering wheel at engine idling
9 to 14
Spin the steering wheel at engine idling
0 to 3
A53763
3. (a)
INSPECT THROTTLE BODY Inspect the throttle control motor for operating sound. (1) Turn the ignition switch ON. (2) When turning the accelerator pedal position sensor lever, check the running sound of the motor. Also, check that there is no friction sound. If operation is not as specified, check the throttle control motor (See page 10–39), wiring and ECM. (b) Inspect the throttle position sensor. (1) Connect the hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) When turning the accelerator pedal position sensor lever to the full–open position, check that the throttle valve opening percentage (THROTTLE POS) of the CURRENT DATA shown the standard value. Standard throttle valve opening percentage: 60 % or more If operation is not as specified, check that the accelerator pedal position sensor (See page 10–39), wiring and ECM. If you have no hand–held tester, measure voltage between terminals (VTA1 – E2, VTA2 – E2) of the ECM connector (See page 05–318). (c) Inspect the air assist system. (1) Start the engine and check that the CHK ENG does not light up. (2) Allow the engine to warm up to normal operating temperature. (3) Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 700 50 rpm NOTICE: Perform inspection under condition without electrical load. (d) After checking the above (b) to (d), perform the driving test and check that there is no sense of incongruity. 4. INSPECT ACCELERATOR PEDAL POSITION SENSOR (a) Connect the hand–held tester to the DLC3. (b) Turn the ignition switch ON. (c) Check that the voltage (ACCEL POS) of the CURRENT DATA shown the standard value. Accelerator pedal released: 0.5 to 1.1 V Accelerator pedal depress: 2.6 to 4.5 V (d) Check that the voltage (ACCEL POS #2) of the CURRENT DATA shown the standard value. Accelerator pedal released: 1.2 to 2.0 V Accelerator pedal depress: 3.4 to 5.3 V If you have no hand–held tester, measure voltage between terminals (VPA – EPA, VPA2 – EPA2) of the ECM connector (See page 05–318).
AVENSIS REPAIR MANUAL (RM1018E)
10–3 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1ZZ–FE/3ZZ–FE) 100EY–02
INSPECTION
1. (a)
Air E2
VG +B THA E2G
5 4 3 2 1
(b) 30 20 RESISTANCE k
10
INSPECT MASS AIR FLOW METER Output voltage inspection. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Connect the positive (+) tester probe to terminal 3 (VG), and negative (–) tester probe to terminal 2 (E2G). (3) Blow air into the MAF meter, and check that the voltage output fluctuates. Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals 4 (THA) and 5 (E2). Resistance:
5 3 2
Terminals
Resistance
Temperature
THA – E2
13.6 to 18.4 k
–20 C (–4 F)
THA – E2
2.21 to 2.69 k
20 C (68 F)
1
THA – E2
0.49 to 0.67 k
60 C (140 F)
2.
0.5 0.3 0.2
(a)
0.1 –20 0 20 40 60 80 100 (–4)(32)(68)(104)(140)(176)(212) TEMPERATUREC(F) A60548 1
2
Valve
A60549
AVENSIS REPAIR MANUAL (RM1018E)
(b)
INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals. Resistance: 6.9 to 7.9 at 20C (68F)
Movement inspection. (1) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm the valve does not adhere. HINT: Bad returning of the valve by catching of foreign objects causes subtle pressure leak to the advanced direction. DTC can be detected.
10–4 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1ZZ–FE/3ZZ–FE)
3. (a)
INSPECT THROTTLE BODY ASSY Check throttle body. (1) Check that throttle valve shaft is not rickety. (2) Check that each port is not stopped up. (3) Check that throttle valve opens and closes smoothly. (4) Check that there is no clearance between the throttle stop screw and throttle lever at the throttle closed position. NOTICE: Do not adjust the throttle stop screw.
1ZZ–FE: Throttle Stop Screw No clearance
Throttle Lever 3ZZ–FE: Throttle Stop Screw
Throttle Lever No clearance
A60621
4. (a)
VTA
E2
VC A60551
INSPECT THROTTLE POSITION SENSOR Resistance inspection. (1) Disconnect the throttle position sensor connector. (2) Using an ohmmeter, measure the resistance between terminals 1 (VC) and 2 (E2). Resistance: 2.5 to 6.0 k (3) Check the variation resistance between terminals 3 (VTA) and 2 (E2). Variation in resistance: The resistance value increases in proportion to the throttle lever opening value.
HINT: Throttle valve
AVENSIS REPAIR MANUAL (RM1018E)
Resistance
Fully open
0.2 to 5.7 k
Fully close
2.0 to 10.2 k
10–5 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1ZZ–FE/3ZZ–FE)
5.
INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Resistance inspection. (1) Using an ohmmeter, measure the resistance between terminals. Resistance: 2.32 to 2.59 kW at 20C (68F) 0.310 to 0.326 kW at 80C (176F) NOTICE: In case of checking the water temperature sensor in the water, be careful not to allow water to go into the terminals, and after checking, wipe out the sensor.
30 20 RESISTANCE kW
10 5 3 2 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (68)(104)(140)(176)(212) TEMPERATUREC(F) A60552
6. (a)
Ohmmeter
INSPECT KNOCK SENSOR Using an ohmmeter, measure the resistance between terminals. Resistance: 120 to 280 kW at 20C (68F)
HINT: If the resistance is not specified, replace the sensor.
A65174
7. (a)
A60553
AVENSIS REPAIR MANUAL (RM1018E)
(b)
INSPECT EFI RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–6 ENGINE CONTROL SYSTEM
8. (a)
A60553
AVENSIS REPAIR MANUAL (RM1018E)
(b)
–
SFI SYSTEM (1ZZ–FE/3ZZ–FE)
INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. Specified condition: Continuity (2) Check that there is no continuity between terminals 3 and 5. Specified condition: No continuity Inspect the relay operation. (1) Apply battery voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. Specified condition: Continuity
10–1 ENGINE CONTROL SYSTEM
–
SFI SYSTEM (1ZZ–FE/3ZZ–FE)
SFI SYSTEM (1ZZ–FE/3ZZ–FE) 100EX–02
ON–VEHICLE INSPECTION 1. (a)
Air
A75903
INSPECT MASS AIR FLOW METER If you have hand–held tester: Inspect for operation (1) Connect the hand–held tester to the DLC3. (2) Turn the ignition switch ON. (3) Blow air into the MAF meter, and check that the air flow fluctuates (MAF) of the ”DIAGNOSIS / OBD/ MOBD / DATA LIST / ALL” shown the standard value. If operation is not as specified, check the MAF meter (See page 10–3), wiring and ECM.
(b)
VG
EVG A79035
If you have no hand–held tester: Inspect for operation (1) Turn the ignition switch ON. (2) Connect the positive tester probe of the voltmeter to the terminal VG of the ECM. and the negative tester probe of the voltmeter to the terminal EVG of the ECM. (3) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, check the MAF meter (See page 10–3), wiring and ECM.
2.
E2
(a)
EMPS A79035
AVENSIS REPAIR MANUAL (RM1018E)
INSPECT POWER STEERING OIL PRESSURE SWITCH Using a voltmeter, measure the voltage between terminals EMPS and E2. Voltage: Condition
Voltage (V)
Not spin the steering wheel at engine idling
8 to 14
Spin the steering wheel at engine idling
0 to 1.5
10–2 ENGINE CONTROL SYSTEM
VaIve Open
Close
Valve 3ZZ–FE: VaIve
Close
Valve A60620
AVENSIS REPAIR MANUAL (RM1018E)
SFI SYSTEM (1ZZ–FE/3ZZ–FE)
3. INSPECT IDLE AIR CONTROL VALVE NOTICE: It is impossible to check the resister value and the operation of ISCV by itself, because the ISCV has an IC circuit inside it, which transforms the duty signal from the ECM to the derive signal. Clear the DTC after inspection. HINT: When the ISCV system has malfunctions except for its adherence, DTC P0505 is detected. (a) Operation inspection. (1) Connect the ISCV connector to the ISCV. (2) Check the valve movement when the ignition switch is turned ON. Movement: Half open fully close fully open half open HINT: ISCV moves within 0.5 second.
1ZZ–FE:
Open
–
10–24 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FE)
THROTTLE BODY ASSY (1AZ–FE) 100FG–01
COMPONENTS Clip
x2
Engine Room Cover Side
x4 Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.lbf)
Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose
VSV Connector
Mass Air Flow Meter Connector Air Cleaner Cap Sub–assy
N·m (kgf·cm, ft·lbf) : Specified torque
Fuel Vapor Feed Hose No. 2 A77870
AVENSIS REPAIR MANUAL (RM1018E)
10–25 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FE)
ISC Valve
ISC Valve Gasket
Throttle Position Sensor
Fuel Vapor Feed Hose
ISC Valve Connector 30 (306, 22)
13 (129, 9)
Accelerator Control Cable Assy
Throttle Position Sensor Connector
Fuel Pipe Support Throttle Body Assy Fuel Tube Sub–assy
Water By–pass Hose Throttle Body Gasket
Water By–pass Hose No. 2
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A77871
10–26 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FE) 100FH–01
Removal & Installation and Disassembly & Reassembly
5 Claws
1. (a) (b)
REMOVE ENGINE ROOM COVER SIDE Remove the retainer and 4 clips. Unfasten the 5 claws and remove the radiator support opening cover.
2. (a)
REMOVE RADIATOR SUPPORT OPENING COVER Remove the 2 clips, and then remove the engine room cover side. DRAIN ENGINE COOLANT (See page 16–19)
A77897
3.
A77902
4. (a)
A77872
AVENSIS REPAIR MANUAL (RM1018E)
REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts, and then remove the engine cover No. 1.
10–27 ENGINE CONTROL SYSTEM
5. (a) (b) (c) (d) (e) (f) (g)
–
THROTTLE BODY ASSY (1AZ–FE)
REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the mass air flow meter connector. Disconnect the VSV connector. Remove the 2 wire harness clamps. Disconnect the ventilation hose. Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose N0. 2. Remove the fuel vapor feed hose No. 2 from 2 clamps of the air cleaner hose. Lock the hose clamp as shown in the illustration. Raise the air cleaner clamp up, slide it to the air cleaner cap. Remove the air cleaner cap together with air cleaner hose No. 1.
(h) (i) (j)
(g)
(h) (g)
(b)
(e)
(c)
(c)
(d)
(f)
(a)
(i)
Air cleaner clamp A77873
6. (a)
A77874
AVENSIS REPAIR MANUAL (RM1018E)
SEPARATE ACCELERATOR CONTROL CABLE ASSY Loosen the nut and separate the accelerator control cable.
10–28 ENGINE CONTROL SYSTEM
(b) (a)
(d)
(c)
–
THROTTLE BODY ASSY (1AZ–FE)
7. (a) (b) (c) (d) (e)
REMOVE THROTTLE BODY ASSY Disconnect the throttle position sensor connector. Disconnect the ISC valve connector. Disconnect the water by–pass hose No. 2. Disconnect the water by–pass hose. Remove the fuel tube from the fuel pipe support.
(f)
Remove the 3 bolts, and then remove the fuel pipe support and the throttle body. Remove the gasket from the intake manifold.
(e) A77875
(g)
A81619
8. (a)
REMOVE FUEL VAPOR FEED HOSE NO.2 Remove the fuel vapor feed hose No. 2 from the throttle body.
9. (a) (b)
REMOVE ISC VALVE Remove the 3 screws, and then remove the ISC valve. Remove the gasket from the throttle body.
10. (a)
REMOVE THROTTLE POSITION SENSOR Remove the 2 screws, and then remove the throttle position sensor.
A77876
A77877
A77878
AVENSIS REPAIR MANUAL (RM1018E)
10–29 ENGINE CONTROL SYSTEM
11. (a) (b)
45
(c) A77879
12. (a) (b) 13. 14. (a) (b)
(c) (d) (e) (f) (g)
15. (a) Rotation Center of Throttle Link
–
THROTTLE BODY ASSY (1AZ–FE)
INSTALL THROTTLE POSITION SENSOR Make sure that throttle valve is fully closed. With the throttle position sensor rotated 45 counterclockwise about the fully closed position of the throttle valve, install the throttle position sensor to the throttle body. Rotate the throttle position sensor clockwise and secure it with the 2 screws. INSTALL ISC VALVE Install a new gasket to the throttle body. Install the ISC valve with the 3 screws. INSTALL FUEL VAPOR FEED HOSE NO.2 INSTALL THROTTLE BODY ASSY Install a new gasket to the intake manifold. Install the throttle body and the fuel pipe support with the 3 bolts. Torque: 30 Nm (306 kgfcm, 22 ftlbf) Install the fuel tube to the fuel pipe support. Connect the water by–pass hose. Connect the water by–pass hose No. 2. Connect the ISC valve connector. Connect the throttle position sensor connector.
INSTALL ACCELERATOR CONTROL CABLE ASSY Instal the accelerator control cable as shown in the illustration. Torque: 13 Nm (129 kgfcm, 9 ftlbf)
83.8 mm (3.299 in.)
A77880
16. 17. 18. 19. 20. 21.
INSTALL AIR CLEANER CAP SUB–ASSY INSTALL ENGINE COVER SUB–ASSY NO.1 Torque: 7.0 Nm (71 kgfcm, 62 in.lbf) ADD ENGINE COOLANT (See page 16–19) CHECK FOR ENGINE COOLANT LEAKS (See page 16–13) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)
10–42 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FSE)
THROTTLE BODY ASSY (1AZ–FSE) 100FI–01
COMPONENTS Clip
x2
Engine Room Cover Side
x4
Clip Retainer Radiator Support Opening Cover
7.0 (71, 62 in.lbf)
Engine Cover Sub–assy No. 1 Fuel Vapor Feed Hose 1.5 (15, 13 in.lbf)
VSV Connector
Mass Air Flow Meter Connector
Air Cleaner Cap Sub–assy
N·m (kgf·cm, ft·lbf) : Specified torque A78507
AVENSIS REPAIR MANUAL (RM1018E)
10–43 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FSE)
Throttle Motor Connector
Throttle Body Assy x4
9.0 (90, 80 in.lbf)
Throttle Body Gasket Water By–pass Hose No. 1
Water By–pass Hose No. 2
x4
Throttle Body Bracket
21 (210, 15)
Ground Terminal
8.4 (86, 74 in.lbf)
Wire Harness Protector
8.4 (86, 74 in.lbf)
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78508
10–44 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FSE) 100FJ–01
REPLACEMENT 1. 2. 3.
REMOVE ENGINE ROOM COVER SIDE (See page 10–26) REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–26) DRAIN ENGINE COOLANT (See page 16–31) 4. (a)
REMOVE ENGINE COVER SUB–ASSY NO.1 Remove the 2 nuts, and then remove the engine cover No. 1.
5. (a) (b) (c) (d) (e) (f) (g) (h)
REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the mass air flow meter connector. Disconnect the VSV connector. Remove the 2 wire harness clamps. Disconnect the ventilation hose. Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 2. Loosen the hose clamp bolt. Raise the air cleaner clamp up, slide it to the air cleaner cap. Remove the air cleaner cap together with the air cleaner hose No. 1.
A78509
(f) (d) (g)
(b) (c)
(d)
(c)
(a)
(i)
(h)
Air Cleaner Clamp
A81620
6. (a)
A78510
AVENSIS REPAIR MANUAL (RM1018E)
REMOVE THROTTLE BODY ASSY Remove the bolt, and then remove the wire harness protector.
10–45 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1AZ–FSE)
(b) (c)
Remove the bolt, and then remove the ground terminal. Remove the 4 bolts, and then remove the throttle body bracket.
(d) (e) (f)
Disconnect the throttle motor connector. Remove the 4 bolts, and then remove the throttle body. Remove the gasket from the intake manifold.
(g) (h)
Disconnect the water by–pass hose No. 1. Disconnect the water by–pass hose No. 2.
(b) A78511
(d)
A78512
(h)
(g) A78513
7. (a) (b) (c) (d) (e) (f) (g) (h) 8. 9. 10. 11. 12.
INSTALL THROTTLE BODY ASSY Connect the water by–pass hose No. 2. Connect the water by–pass hose No. 1. Install a new gasket to the intake manifold. Install the throttle body with the 4 bolts. Torque: 9.0 Nm (90 kgfcm, 80 in.lbf) Connect the throttle motor connector. Install the throttle body bracket with the 4 bolts. Torque: 21 Nm (210 kgfcm, 15 ftlbf) Install the ground terminal with the bolt. Torque: 8.4 Nm (86 kgfcm, 74 in.lbf) Install the wire harness protector with the bolt. Torque: 8.4 Nm (86 kgfcm, 74 in.lbf) INSTALL AIR CLEANER CAP SUB–ASSY Torque: 1.5 Nm (15 kgfcm, 13 in.lbf) INSTALL ENGINE COVER SUB–ASSY NO.1 Torque: 7.0 Nm (71 kgfcm, 62 in.lbf) ADD ENGINE COOLANT (See page 16–31) CHECK FOR ENGINE COOLANT LEAKS (See page 16–25) INSTALL ENGINE ROOM COVER SIDE
AVENSIS REPAIR MANUAL (RM1018E)
10–46 ENGINE CONTROL SYSTEM
13.
–
THROTTLE BODY ASSY (1AZ–FSE)
INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)
10–7 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1ZZ–FE)
THROTTLE BODY ASSY (1ZZ–FE) 100FB–01
COMPONENTS Clip
x2
Engine Room Cover Side
Clip x4 Retainer Radiator Support Opening Cover
Clip 7.0 (71, 62 in.·lbf)
Cylinder Head Cover No.2 Accelerator Control Cable Assy 13 (129, 9)
Fuel Vapor Feed Hose No.1 VSV Connector
1.5 (15, 13 in.·lbf)
Mass Air Flow Meter Connector
Air Cleaner Cap Sub–assy Fuel Vapor Feed Hose No.3
N·m (kgf·cm, ft·lbf) : Specified torque A78454
AVENSIS REPAIR MANUAL (RM1018E)
10–8 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1ZZ–FE)
Ventilation Hose
x2 13 (133, 10)
Throttle Body Assy
M/T: Manifold Stay No.2
30 (306, 22)
Throttle Position Sensor Connector
Water By–pass Hose No.2 Throttle Body Gasket
Water By–pass Hose
ISC Valve Connector
Throttle Body Bracket
30 (306, 22)
x2 2.0 (20, 18 in.·lbf)
Throttle Position Sensor
Accelerator Control Cable Bracket x2 13 (133, 10)
Throttle Body Cover Gasket ISC Valve
3.7 (38, 33 in.·lbf)
x3
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78455
10–9 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (1ZZ–FE) 100FC–01
Removal & Installation and Disassembly & Reassembly
5 Claws
1. (a) (b)
REMOVE RADIATOR SUPPORT OPENING COVER Remove the retainer and 4 clips. Unfasten the 5 claws and remove the radiator support opening cover.
2. (a)
REMOVE ENGINE ROOM COVER SIDE Remove the 2 clips, and then remove the engine room cover side. DRAIN ENGINE COOLANT (See page 16–7)
A78457
3.
A78458
4. (a)
A78459
AVENSIS REPAIR MANUAL (RM1018E)
REMOVE CYLINDER HEAD COVER NO.2 Remove the 2 nuts and 2 clips, and then remove the cylinder head cover No. 2.
10–10 ENGINE CONTROL SYSTEM
5. (a) (b) (c) (d) (e) (f)
(d)
(e)
(b)
(c)
(f) (g)
(c)
(g) (h)
(a)
(i)
–
THROTTLE BODY ASSY (1ZZ–FE)
REMOVE AIR CLEANER CAP SUB–ASSY Disconnect the mass air flow meter connector. Disconnect the VSV connector. Remove the 2 wire harness clamps. Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 3. Remove the accelerator control cable from the accelerator control cable support No. 2. Loosen the hose clamp. Raise the air cleaner clamp up, slide it to the air cleaner cap. Remove the air cleaner cap together with the air cleaner hose No. 1.
(h)
Air Cleaner clamp A78460
6. (a)
SEPARATE ACCELERATOR CONTROL CABLE ASSY Loosen the nut and separate the accelerator control cable.
7. (a) (b) (c)
REMOVE THROTTLE BODY ASSY Disconnect the water by–pass hose. Disconnect the water by–pass hose No. 2. Disconnect the ventilation hose.
(d) (e) (f)
Disconnect the throttle position sensor connector. Disconnect the ISC valve connector. Remove the 3 bolts and 2 nuts, and then remove the throttle body bracket and the throttle body. (A/T) Remove the 5 bolts and 2 nuts, and then remove the throttle body bracket and the throttle body. (M/T) Remove the gasket from the intake manifold.
A78461
(c) (b) (a)
A78462
(M/T)
(g)
(d)
(h) (e) AVENSIS REPAIR MANUAL (RM1018E)
A78463
10–11 ENGINE CONTROL SYSTEM
8. (a)
–
THROTTLE BODY ASSY (1ZZ–FE)
REMOVE ACCELERATOR CONTROL CABLE BRACKET Remove the 2 bolts, and then remove the accelerator control cable bracket.
A78464
9. (a) (b)
REMOVE ISC VALVE Remove the 3 screws, and then remove the ISC valve. Remove the gasket from the throttle body.
10. (a)
REMOVE THROTTLE POSITION SENSOR Remove the 2 screws, and then remove the throttle position sensor.
11. (a) (b)
INSTALL THROTTLE POSITION SENSOR Make sure that the throttle valve is fully closed. With the throttle position sensor rotated 30 to 45 counterclockwise about the fully closed position of the throttle valve, install the throttle position sensor to the throttle body. Rotate the throttle position sensor clockwise and secure it with the 2 screws. Torque: 2.0 Nm (20 kgfcm, 18 in.lbf) INSTALL ISC VALVE Install a new gasket to the throttle body. Install the ISC valve with the 3 screws. Torque: 3.7 Nm (38 kgfcm, 33 in.lbf) INSTALL ACCELERATOR CONTROL CABLE BRACKET Torque: 13 Nm (133 kgfcm, 10 ftlbf)
A78465
A78466
30 to 45
(c) A78467
12. (a) (b) 13.
AVENSIS REPAIR MANUAL (RM1018E)
10–12 ENGINE CONTROL SYSTEM
14. (a) (b)
A
B B
A
(d) A
(c)
A
A
(c) A78463
(d) (e) (f) (g) (h)
15. (a)
Rotation Center of Throttle Link
18
16. 17. 18. 19. 20. 21.
–
THROTTLE BODY ASSY (1ZZ–FE)
INSTALL THROTTLE BODY ASSY Install a new gasket to the intake manifold. Install the throttle body and the throttle body bracket with the 3 bolts and 2 nuts. (A/T) Torque: 30 Nm (306 kgfcm, 22 ftlbf) for bolt and nut A Install the throttle body and the throttle body bracket with the 5 bolts and 2 nuts. (M/T) Torque: 30 Nm (306 kgfcm, 22 ftlbf) for bolt and nut A 13 Nm (133 kgfcm, 10 ftlbf) for bolt B Connect the ISC valve connector. Connect the throttle position sensor connector. Connect the ventilation hose. Connect the water by–pass hose No. 2. Connect the water by–pass hose.
INSTALL ACCELERATOR CONTROL CABLE ASSY Install the accelerator control cable as shown in the illustration. Torque: 13 Nm (129 kgfcm, 9 ftlbf)
65.1 mm (2.563 in.) A78468
INSTALL AIR CLEANER CAP SUB–ASSY Torque: 1.5 Nm (15 kgfcm, 13 in.lbf) INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 Nm (71 kgfcm, 62 in.lbf) ADD ENGINE COOLANT (See page 16–7) CHECK FOR ENGINE COOLANT LEAKS (See page 16–1) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)
10–13 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (3ZZ–FE)
THROTTLE BODY ASSY (3ZZ–FE) 100FD–01
COMPONENTS Clip
x2
Engine Room Cover Side
Clip x4 Retainer Radiator Support Opening Cover
Clip 7.0 (71, 62 in.·lbf)
Cylinder Head Cover No.2 Accelerator Control Cable Assy 13 (129, 9)
Fuel Vapor Feed Hose No.1 VSV Connector
1.5 (15, 13 in.·lbf)
Mass Air Flow Meter Connector
Air Cleaner Cap Sub–assy Fuel Vapor Feed Hose No.3
N·m (kgf·cm, ft·lbf) : Specified torque A78454
AVENSIS REPAIR MANUAL (RM1018E)
10–14 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (3ZZ–FE)
Accelerator Control Cable Bracket 30 (306, 22)
Ventilation Hose
Throttle Position Sensor Connector Water By–pass Hose No.2 Water By–pass Hose
Throttle Body Gasket
Throttle Body Assy
x2
30 (306, 22)
ISC Valve Connector
x2
2.0 (20, 18 in.·lbf)
Throttle Position Sensor
Throttle Body Cover Gasket
ISC Valve
3.7 (38, 33 in.·lbf)
x4
N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part AVENSIS REPAIR MANUAL (RM1018E)
A78504
10–15 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (3ZZ–FE) 100FE–01
Removal & Installation and Disassembly & Reassembly 1. 2. 3. 4. 5.
REMOVE RADIATOR SUPPORT OPENING COVER (See page 10–9) REMOVE ENGINE ROOM COVER SIDE (See page 10–9) DRAIN ENGINE COOLANT (See page 16–7) REMOVE CYLINDER HEAD COVER NO.2 (See page 10–9) REMOVE AIR CLEANER CAP SUB–ASSY (See page 10–9)
6. (a)
SEPARATE ACCELERATOR CONTROL CABLE ASSY Loosen the nut and separate the accelerator control cable.
7. (a) (b) (c)
REMOVE THROTTLE BODY ASSY Disconnect the ventilation hose. Disconnect the water by–pass hose. Disconnect the water by–pass hose No. 2.
(d) (e) (f) (g)
Disconnect the throttle position sensor. Disconnect the ISC valve connector. Remove the bolt and 2 nuts, and then remove the accelerator control bracket and the throttle body. Remove the gasket from the intake manifold.
8. (a) (b)
REMOVE ISC VALVE Remove the 4 screws, and then remove the ISC valve. Remove the gasket from the throttle body.
A78497
(c) (a) (b)
A78498
(d)
(e) A78499
A78500
AVENSIS REPAIR MANUAL (RM1018E)
10–16 ENGINE CONTROL SYSTEM
–
THROTTLE BODY ASSY (3ZZ–FE)
9. (a)
REMOVE THROTTLE POSITION SENSOR Remove the 2 screws, and then remove the throttle position sensor.
10. (a) (b)
INSTALL THROTTLE POSITION SENSOR Make sure that the throttle valve is fully closed. With the throttle position sensor rotated 30 to 45 counterclockwise about the fully closed position of the throttle valve, install the throttle position sensor to the throttle body. Rotate the throttle position sensor clockwise and secure it with the 2 screws. Torque: 2.0 Nm (20 kgfcm, 18 in.lbf) INSTALL ISC VALVE Install a new gasket to the throttle body. Install the ISC valve with the 4 screws. Torque: 3.7 Nm (38 kgfcm, 33 in.lbf) INSTALL THROTTLE BODY ASSY Install a new gasket to the intake manifold. Install the throttle body and the accelerator control bracket with the bolt and 2 nuts. Torque: 30 Nm (306 kgfcm, 22 ftlbf)
A78501
30 to 45
(c) A78503
11. (a) (b) 12. (a) (b)
13. (a)
Rotation Center of Throttle Link
66.3 mm 11 (2.610 in.)
14. 15. 16. 17. 18. 19.
INSTALL ACCELERATOR CONTROL CABLE ASSY Install the accelerator control cable as shown in the illustration. Torque: 13 Nm (129 kgfcm, 9 ftlbf)
A78469
INSTALL AIR CLEANER CAP SUB–ASSY (See page 10–9) INSTALL CYLINDER HEAD COVER NO.2 (See page 10–9) ADD ENGINE COOLANT (See page 16–7) CHECK FOR ENGINE COOLANT LEAKS (See page 16–1) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER
AVENSIS REPAIR MANUAL (RM1018E)