132

INTAKE INTAKE AIR CONTROL SYSTEM (1AZFSE)

INSPECTION

1. (a)

A79032

INSPECT INTAKE AIR CONTROL VALVE ASSY With 34.7 kPa (260 mm Hg, 10.2 in. Hg) of vacuum applied to the actuator, check that the actuator rod moves. (b) One minute after applying the vacuum, check that the actuator rod does not return. (c) If the operation is not as specified, replace the intake air control valve assembly. NOTICE: Do not touch the adjust screw. 2. (a) INSPECT VACUUM SWITCHING VALVE ASSY NO.1 Using an ohmmeter, measure resistance between each terminal. Resistance: 33 to 39 W at 20_C (68_F) Check that air flows form port B to the filter. Apply battery voltage across the terminals. Check that air flows from port B to port A.

Filter

(b) (c) (d)

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INTAKE INTAKE AIR CONTROL SYSTEM (1AZFSE)

INTAKE AIR CONTROL SYSTEM (1AZFSE)

ONVEHICLE INSPECTION
1. (a) (b) (c) (d) INSPECT INTAKE AIR CONTROL SYSTEM Using a 3way connector, connect vacuum gauge to the actuator hose. Connect the handheld tester to the DLC 3. Start the engine. Select the active test mode according to the message on the handheld tester. Vacuum:
VSV ON VSV OFF Approx. 27 kPa (200 mm Hg, 7.9 in. Hg) 0 kPa (0 mm Hg, 0 in. Hg.)

Vacuum Gage

A77131

SCV VSV

(e)

Throttle Valve Open Position

100

ON
35.7

(f) HINT: The value in the illustration is only for reference; the throttle valve may operate diversely depend on the engine running condition.

Shift the transmission into the P range and control the accelerator pedal. Check the VSV operation using the hangheld tester.

OFF
3700

Engine Speed [r/min.]

AVENSIS REPAIR MANUAL (RM1018E)

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INTAKE INTERCOOLER ASSY (1CDFTV)

INTERCOOLER ASSY (1CDFTV)

REPLACEMENT
1. REMOVE FRONT BUMPER COVER (See page 763) 2. (a) REMOVE INTERCOOLER COOLING AIR DUCT SUBASSY Remove the 2 bolts and the cooling air duct.

A79168

3. (a)

REMOVE INTERCOOLER ASSY Disconnect the vacuum hose, the air hose No. 2 and No. 3 from the intercooler.

A80112

(b) 4. (a)

Remove the 3 bolts and nut, and then detach the intercooler assy. INSTALL INTERCOOLER ASSY Install the intercooler assembly with the 3 bolts and a new nut. Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf)

A80113

(b)

Install the air hose and hose clamps as shown in the illustration.

2 to 7 mm

0 to 5 mm

A64328

AVENSIS REPAIR MANUAL (RM1018E)

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INTAKE INTERCOOLER ASSY (1CDFTV)

(c)

Tighten the hose clamps as shown in the illustration. Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf)

Front

90_ Clamp Bolt

A64007

5. 6.

INSTALL INTERCOOLER COOLING AIR DUCT SUBASSY Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) INSTALL FRONT BUMPER COVER (See page 763)

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INTAKE TURBO CHARGER SYSTEM (1CDFTV)
1303002

INSPECTION

1. (a)

VACUUM SWITCHING VALVE ASSY NO.1 Inspect VSV for open circuit. (1) Using an ohmmeter, check that the there is continuity between the terminals. Resistance: 37 44 W at 20_C (68_F)

A60591

(b)

Inspect VSV for ground. (1) Using an ohmmeter, check that there is no continuity between each terminal and the body. Specified condition: No continuity

A60592

Air

(c)

Inspect VSV operation. (1) Check that air flows from port E to G.

E G

A60593

Air

(2) (3)

Apply battery voltage across the terminals. Check that air flows from port E to filter.

E Filter

Battery
A60594

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INTAKE TURBO CHARGER SYSTEM (1CDFTV)
1302Z03

ONVEHICLE INSPECTION
1. (a) INSPECT INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner housing and turbocharger inlet and between the turbocharger outlet and cylinder head. (1) Clogged air cleaner...Clean or replace element (2) Hoses collapsed or deformed...Repair or replace (3) Leakage from connections...Check each connection and repair (4) Cracks in components...Check and replace INSPECT EXHAUST SYSTEM Check for leakage or clogging between the cylinder head and turbocharger inlet and between the turbocharger outlet and exhaust pipe. (1) Deformed components...Repair or replace (2) Foreign material in passages...Remove (3) Leakage from components...Repair or replace (4) Cracks in components...Check and replace

2. (a)

SST

3. (a) (b)

A77123

CHECK TURBOCHARGING PRESSURE Warm up the engine. Using a 3way connector, connect SST (turbocharger pressure gauge) to the hose leading to the intake air connector. SST 09992 00242 (c) While depressing the clutch pedal, press the accelerator pedal down to the full. Measure the turbocharging pressure at maximum speed (5,100 to 5,250 rpm). Standard pressure: 15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.2 to 6.5 psi) If the pressure is less than specification, check both the intake air and exhaust systems for leakage. If there is no leakage, check if the actuator hose has disconnected. If not, check the turbocharger. If the pressure is greater than specification, check if the actuator hose has disconnected or cracked. If not, check the turbocharger.

4. (a)

E2

VC

A60595

INSPECT TURBO PRESSURE SENSOR Inspect power source voltage (1) Disconnect the turbo pressure sensor connector. (2) Turn the ignition switch ON. (3) Using a voltmeter, measure the voltage between connector terminals 3 (VC) and 1 (E2) of the wiring harness side. Voltage: 4.5 to 5.5 V (4) Turn the ignition switch OFF. (5) Reconnect the turbo pressure sensor connector.

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INTAKE TURBO CHARGER SYSTEM (1CDFTV)

(b)
ECM

E2 ()

PIM (+)

SST

Inspect supply power (1) Turn the ignition switch ON. (2) Disconnect the vacuum hose from the turbo pressure sensor. (3) Connect a voltmeter to terminals 35 (PIM) and 28 (E2) of the ECM and measure the output voltage under atmospheric pressure. (4) Apply vacuum to the turbo pressure sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.96 in.Hg). (5) Measure the voltage decrease from step (3) above for each segment. Voltage drop:
Apply Vacuum [kPa (mmHg, in.Hg)] 13.3 (100, 3.94) Voltage Decrease [V] 0.1 to 0.3 0.3 to 0.5 0.5 to 0.7 0.7 to 0.9 0.9 to 1.0

Vacuum
A79448

26.7 (200, 7.87) 40.0 (300, 11.81) 57.3 (400, 15.75) 66.7 (500, 19.96)

(6)
SST Pressure

Using SST (turbocharger pressure gauge), apply pressure to the turbo pressure sensor in 19.6 kPa (0.20 kgf/cm2, 2.84 psi) segments to 98.0 kPa (1.00 kgf/cm2, 14.2 psi). SST 0999200242 (7) Measure the voltage increase from step (3) above for each segment. Voltage up:
Applied Pressure [kPa (kgf/cm2, psi)] 19.6 (0.20, 2.84) 39.2 (0.40, 5.69) 58.8 (0.60, 8.53) 78.5 (0.80, 11.4) 98.0 (1.00, 14.2) Voltage Increase [V] 0.1 to 0.4 0.4 to 0.7 0.7 to 1.0 1.0 to 1.3 1.3 to 1.6

A77125

AVENSIS REPAIR MANUAL (RM1018E)

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INTAKE TURBO CHARGER SYSTEM (1CDFTV)

TURBO CHARGER SYSTEM (1CDFTV)

PRECAUTION
1. (a) MAINTENANCE PRECAUTION Do not stop the engine immediately after pulling a trailer, or after driving at a high speed, or uphill drive. Let the engine Idle for 20 to 120 seconds before turn the ignition switch OFF (According as the driving condition, the idling time varies). Avoid quick acceleration or quickly accelerating the engine RPM immediately after the starting a cold engine. If the turbocharger is found to be defective, it must be replaced. Also, inspect a source of the trouble including conditions of the turbocharger that having been used. Repair or replace the followings as necessary: (1) Engine oil (Level and quality) (2) Oil lines leading to the turbocharger

(b) (c)

(d)

(e)

Pay due attention when removing and reinstalling the turbocharger assembly. Do not drop, or do not give shock, or do not grasp easilydeformed assembly parts such as the actuator or push rod in removal and reinstallation. Before removal, cover both the intake and exhaust ports and the oil inlet to prevent dirt or foreign objects from being introduced.

A77119

(f) (g) (h)

If replacing the turbocharger, check for deposits in the oil pipe. If necessary, replace the oil pipe too. Thoroughly remove old gasket sticking to the lubrication oil pipe flange and the turbocharger oil flange. If replacing the bolt(s) or nut(s), must use Toyota genuine parts to prevent breakage or deformation.

A77120

(i)

(j)

If replacing the turbocharger, put 20 cm3 (1.2 cu in.) of fresh oil into the turbocharger oil inlet hole and turn the turbine wheel by hand to spread oil to the bearing. If overhauling or replacing the engine, cut the fuel supply after reassembly and crank the engine for 30 seconds to feed oil throughout the engine then run the engine at idle for 60 seconds.

A77121

AVENSIS REPAIR MANUAL (RM1018E)

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INTAKE TURBO CHARGER SYSTEM (1CDFTV)

(k)

Since the turbine wheels runs at an extremely high speed, if the engine is running without the air cleaner, case cover and hose, damage to the turbine wheel will result by introduced foreign particle.

A77122

AVENSIS REPAIR MANUAL (RM1018E)

138
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

TURBOCHARGER SUBASSY (1CDFTV)

COMPONENTS

Clip

Retainer
8.0 (82, 71 in.Vlbf)

Radiator Support Opening Cover

Engine Cover No. 1

Air Cleaner Cap w/ Hose

Air Cleaner Element Air Cleaner Case

Engine Under Cover Subassy No. 1

Clip Nm (kgfcm, ftlbf) : Specified torque

AVENSIS REPAIR MANUAL (RM1018E)

139
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

Union To Connector Tube Hose Vacuum Reservoir Subassy

7.5 (76, 66 in.Vlbf) 8.3 (85, 73 in.Vlbf)

w/ Cold Area: Heater Bracket w/ Cold Area: Heater Pump Assy

25 (255, 18)

Fuel Filter Assy

Air Tube No. 1

Intercooler Air Hose

Compression Spring z Gasket

Exhaust Pipe Assy Front z Gasket Floor Panel Brace Front

30 (302, 22) 43 (440, 32) 7.5 (76, 66 in.Vlbf)

Compression Spring

z Gasket Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

7.5 (76, 66 in.Vlbf)

w/ Cold Area: Exhaust Pipe Assy

1310
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

Turbo Insulator No. 1

Exhaust Manifold Heat Insulator No. 2

Turbo Insulator No. 2 Turbocharger Stay

56 (571, 41)

z z Gasket

53 (540, 39)

Turbocharger Subassy

25 (255, 18)

z Gasket Manifold Stay No. 2

z Gasket Turbo Oil Inlet Pipe Subassy Turbo Water Hose No. 2 z Gasket
36 (367, 27)

56 (571, 41)

Exhaust Manifold Converter Subassy

61 (622, 45)

Manifold Stay

Turbo Water Hose No. 1

13 (135, 9.7)

Turbo Water Pipe Subassy No. 1

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

1311
INTAKE TURBOCHARGER SUBASSY (1CDFTV)
1306Z01

REPLACEMENT
1. 2. 3. 4. (a) REMOVE ENGINE UNDER COVER SUBASSY NO.1 DRAIN ENGINE COOLANT (See page 1644) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover.

5. (a) (b)

REMOVE VACUUM RESERVOIR SUBASSY Disconnect the 2 vacuum hoses and the connector. Remove the 2 bolts and the vacuum reservoir.

A79155

6. (a) (b) (c) (d)

REMOVE AIR CLEANER ASSY Disconnect the PCV hose and the connector. Remove the air cleaner cap with the air cleaner hose. Remove the air cleaner filter element. Remove the 3 bolts and the air cleaner case. 7. REMOVE INTERCOOLER AIR HOSE (a) Remove the 3 bolts and nut, separate the air tube No.1. (b) Loosen the hose clamp bolts and remove the air hose No.1.

A80093

8.

REMOVE FUEL FILTER ASSY (See page 1182)

9. (a) (b)

SEPARATE HEATER PUMP ASSY (W/ COLD AREA) Remove the nut and disconnect the connector. Separate the heater pump.

A79158

AVENSIS REPAIR MANUAL (RM1018E)

1312
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

10. (a)

REMOVE HEATER BRACKET (W/ COLD AREA) Remove the bolt and the heater bracket.

A79159

11. 12.

REMOVE FLOOR PANEL BRACE FRONT (See page 1510) REMOVE EXHAUST PIPE ASSY FRONT (See page 1510)

13. (a)

REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) Remove the 2 nuts.

A79156

(b)

Remove the 2 nuts and the exhaust pipe subassy.

A79157

14. (a)

REMOVE TURBO INSULATOR NO.2 Remove the 4 bolts and the turbo insulator.

A79160

AVENSIS REPAIR MANUAL (RM1018E)

1313
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

15. (a)

REMOVE TURBO INSULATOR NO.1 Remove the 2 bolts and nut, and then remove the turbo insulator.

A79161

16. (a)

REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 Remove the 2 bolts and the exhaust manifold heat insulator.

A79162

17. (a)

REMOVE MANIFOLD STAY NO.2 Remove the bolt and nut and then remove the manifold stay.

A79163

18. (a)

REMOVE MANIFOLD STAY Remove the 4 bolts and the manifold stay.

A79164

19. (a)

REMOVE EXHAUST MANIFOLD CONVERTER SUBASSY Remove the 3 nuts, the manifold converter and the gasket.

A79444

AVENSIS REPAIR MANUAL (RM1018E)

1314
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

20. (a)

REMOVE TURBOCHARGER STAY Remove the 2 bolts and 2 nuts, and then remove the turbocharger stay.

A79165

21.

DISCONNECT TURBO WATER HOSE NO.1

A79166

22.

DISCONNECT TURBO WATER HOSE NO.2

A79167

23. (a)

SEPARATE TURBO OIL INLET PIPE SUBASSY Remove the 2 nuts, the turbo oil pipe and the gasket.

B13094

24. (a)

REMOVE TURBOCHARGER SUBASSY Remove the 3 nuts, the turbocharger and the gasket.

B13095

AVENSIS REPAIR MANUAL (RM1018E)

1315
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

25. (a)

REMOVE TURBO WATER PIPE SUBASSY NO.1 Remove the 2 nuts, the turbo water pipe and the gasket.

B13096

26. (a) 27. (a) 28. (a)

INSTALL TURBO WATER PIPE SUBASSY NO.1 Install a new gasket and the turbo water pipe with the 2 nuts. Torque: 13 NVm (135 kgfVcm, 9.7 ftVlbf) INSTALL TURBOCHARGER SUBASSY Install a new gasket and the turbocharger with the 3 nuts. Torque: 53 NVm (540 kgfVcm, 39 ftVlbf) INSTALL TURBO OIL INLET PIPE SUBASSY Install a new gasket and the oil pipe with the 2 nuts. Torque: 13 NVm (135 kgfVcm, 9.7 ftVlbf) 29. (a) (b) INSTALL TURBOCHARGER STAY Install the turbocharger stay, and temporarily tighten bolt A. Temporarily tighten nut B while pushing the cylinder head toward the turbocharger stay. Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) Tighten bolt A. Torque: 56 NVm (571 kgfVcm, 41 ftVlbf) Tighten nut B. Torque: 56 NVm (571 kgfVcm, 41 ftVlbf) INSTALL EXHAUST MANIFOLD CONVERTER SUBASSY Install the manifold stay, and temporarily tighten the cylinder block side of the manifold stay.

(c)
B A A
A79165

(d) 30. (a)

AVENSIS REPAIR MANUAL (RM1018E)

1316
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

(b)

(c) (d) (e)

Install a new gasket and the manifold converter, and temporarily tighten bolts A and bolts B while pushing the upper portion of the converter toward the turbocharger. Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) Tighten the 3 nuts. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf) Tighten bolts A. Torque: 61 NVm (622 kgfVcm, 45 ftVlbf) Tighten bolts B. Torque: 61 NVm (622 kgfVcm, 45 ftVlbf)

A A

B
A79444 A79164

A80106

31. (a) (b)

INSTALL MANIFOLD STAY NO.2 Install the manifold stay No. 2, and temporarily tighten the bolt. Temporarily tighten the nut while pushing the manifold stay No. 2 toward the cylinder head. Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)

32. 33. 34. 35. 36. 37. 38. 39. 40.

HINT: No clearance between the stay and the cylinder head should be confirmed. A79163 (c) Tighten the bolt. Torque: 56 NVm (571 kgfVcm, 41 ftVlbf) (d) Tighten the nut. Torque: 56 NVm (571 kgfVcm, 41 ftVlbf) INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 Torque: 12 NVm (122 kgfVcm, 8.9 ftVlbf) INSTALL TURBO INSULATOR NO.1 Torque: 20 NVm (204 kgfVcm, 15 ftVlbf) INSTALL TURBO INSULATOR NO.2 Torque: 20 NVm (204 kgfVcm, 15 ftVlbf) INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf) INSTALL EXHAUST PIPE ASSY FRONT (See page 1510) INSTALL FLOOR PANEL BRACE FRONT (See page 1510) INSTALL HEATER BRACKET (W/ COLD AREA) Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf) INSTALL HEATER PUMP ASSY (W/ COLD AREA) Torque: 7.5 NVm (76 kgfVcm, 66 in.Vlbf) INSTALL FUEL FILTER ASSY (See page 1182)

AVENSIS REPAIR MANUAL (RM1018E)

1317
INTAKE TURBOCHARGER SUBASSY (1CDFTV)

41. (a)
2 to 7 mm 0 to 2 mm

INSTALL INTERCOOLER AIR HOSE Install the air hose and hose clamps as shown in the illustration.

A64328

(b)
Upward

(c)

Tighten the hose clamps as shown in the illustration. Torque: 6.0 NVm (61 kgfVcm, 53 in.Vlbf) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)

90_ Clamp Bolt

42. 43. 44. 45. 46. 47. 48. 49. 50.

INSTALL AIR CLEANER ASSY Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf) INSTALL VACUUM RESERVOIR SUBASSY Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf) INSTALL ENGINE COVER NO.1 Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) ADD ENGINE COOLANT (See page 1644) CHECK ENGINE OIL LEVEL CHECK FOR ENGINE COOLANT LEAKS (See page 1644) CHECK FOR ENGINE OIL LEAKS CHECK FOR FUEL LEAKS (See page 1160) CHECK FOR EXHAUST GAS LEAKS

AVENSIS REPAIR MANUAL (RM1018E)