Model Outline

 Line-off
• Desember, 2003

 Model Line-up
Transmisi
Tipe (Manual 5-kecepatan)
Tujuan Mesin Grade
Body
M5S-B9 M5S-C9

F600RV-GMREJ _ Mi
EJ-DE
(1.0L)
Van F600RV-GMDEJ _ Li
Indonesia
5-Pintu
Xi Xenia
K3-DE F601RV-
_ E,G
(1.3L) GMDEJ
Avanza
Model Outline AVANZA
 Model Code

F601 R M –G M D E J
1 2 3 4 5 6 7 8

Basic Model Code Gear Shift Type

1 5
F601: K3-DE Engine M: 5-speed Manual

Steering Wheel Position Grade

2 6
R: Right-Hand Drive D: E M: G

Model Name Engine Specification

3 7
M: VAN (TOYOTA) E: 4-valve EFI

Body Type Destination

4 8
G: 5-door J: Indonesia
Model Outline XENIA
 Kode Model
F6 0 0 R V –G M D E J
1 2 3 4 5 6 7 8 9 10
Nama Model Pintu
1 6
F6: XENIA G: 5 Pintu

Tipe Penggerak Tipe Transmisi

2 7
0: Penggerak 2 roda (2WD) M: Manual 5-kecepatan

Mesin Grade
3 0: Mesin EJ-DE 8 R: Mi (EJ-DE)
1: Mesin K3-DE D: Li (EJ-DE)
Xi (K3-DE)
Posisi Roda Kemudi Spesifikasi Mesin
4 9
R: Steer Kanan E: 4-valve EFI

Tipe Bodi Tujuan

5 10
V: Van J: Indonesia
Model Outline
 Front View
Model Outline
 Rear View
Model Outline Card Holder

 Interior
Model Outline
Storage
 Interior Space

Dealer option

Seat Arrangement
Model Outline AVANZA
 Interior
• Combination Meter
– Large, easy-to-read colored dials and silver
metering for elegant look
Model Outline XENIA
 Interior
• Meter Kombinasi
– Besar, jarum mudah dibaca, terlihat elegant
Model Outline
 Equipment
• Cooler System
– Double blower manual cooler (G grade)
Model Outline
 Equipment
• Audio System
– 1 DIN type AM/FM radio
cassette with 4-speaker
(G grade)

Deutsche Industry Norm (H x W)

•1 DIN: 50 mm x 150 mm
•2 DIN: 100 mm x 180 mm
Model Outline
 Power Train
• Engine
– AVANZA uses K3-DE leaded gasoline engine

K3-DE:
L4, 1.3 liter
DIS
DOHC
Mesin
 Mesin Overall
• Line-up
– XENIA menggunakan mesin K3-DE dan EJ-DE

K3-DE EJ-DE
Model Outline AVANZA
 Tire and Disc Wheel
Grade G E

Tire Size 185/70R14

Size 14 x 5.0 JJ
Disc
Wheel
Material Aluminum Steel w/ Full Cap

Wheel Design
Model Outline XENIA
 Ban dan Velg
Grade Mi & Li Xi
Ban Ukuran 165/80R13 185/70R14
Ukuran 13 x 5.0 J 14 x 5.0 J
P.C.D 114,3 mm 114,3 mm
Velg
Off Set 45 mm 50 mm
Material Baja

Rancangan
Engine
 Engine Overall
• Engine number location
Mesin
 Spesifikasi mesin
Item K3-DE EJ-DE
Jumlah Silinder dan Susunan Segaris 4-silinder Segaris, 3-silinder
Mekanisme Valve 16-Valve DOHC, Chain Drive 12-Valve DOHC, Belt Drive
Isi cm3 1297 989
Bore x stroke mm 72.0 X 79.7 72.0 X 81.0
Rasio Kompresi 10.0 
Max. Output 63 kW @ 6000 rpm 42 kW @ 5200 rpm
Max. Torque 117 N·m@ 3200 rpm 90 N·m@ 3600 rpm
Buka 8° BTDC 4° BTDC
Intake
Valve Tutup 32° ABDC 42° ABDC
Timing Buka 30° BBDC 44° BBDC
Exhaust
Tutup 2° ATDC 6° ATDC
Sistem Bahan Bakar EFI Tipe-D 
Sistem Pengapian Full Transistorized DLI 
Research Octane Number 90 atau lebih, Bertimbal 
Oil Grade, Viscositas API SJ atau SL, SAE 20W-50 
Engine
 Engine Proper
• Features of K3-DE Engine
– L4, 1.3-liter, 16-valve, DOHC, leaded gasoline
engine with DIS
Stepper Motor
DIS Type ISC

LLC Plastic type

Intake Manifold

Stainless Steel
Exhaust Manifold

Flexible
Flywheel

Manifold Pressure
Sensor
Engine
 Engine Proper
• Features of K3-DE Engine

Air
Bleeder

Serpentine
Drive Belt

Aluminum
Oil Pan
Mesin
 Mesin Keseluruhan
• Keistimewaan dari mesin EJ-DE
– L3, 1.0-liter, 12-valve, DOHC, bensin bertimbal
dengan DLI
ISC tipe
Stepper Motor
DIS

LLC

Flexible
Flywheel

Manifold Pressure
Sensor
Mesin
 Perbedaan Utama (K3-DE  EJ-DE)

Item K3-DE EJ-DE

Mekanisme Valve Chain drive Belt drive

Valve Lifter Tipe Tanpa Shim Tipe Outer Shim

Digerakan oleh
Pompa Oli Digerakan oleh rantai
crankshaft

Oil Pan Aluminum Baja

Intake Manifold Plastik Baja

DLI DLI
Sistem Pengapian (2 Ignition Coil / 4 (3 Ignition Coil / 3
Silinder) Silinder)
Mesin
 Kelengkapan Mesin
• Flywheel
– Flexible flywheel untuk mengurangi vibrasi saat
berputar dari vibrasi bengkokan crankshaft

K3-DE EJ-DE
Engine
 Engine Proper
• Flywheel
– Flexible flywheel
 Operation

Reduces
vibration

Vibration

Flexible Plate

Flexible Type Normal Type

Engine
 Valve Mechanism
• Timing Chain

Chain Drive
Valve Mechanism

Tensioner
Service Plug

Chain Driven Oil Pump

Mesin Scissor
Gear
 Mekanisme Valve (EJ-DE)
• Timing Belt

Tanda Timing

Drain Plug
(Pada Pompa Air)

Timing Belt

Tanda Timing
Engine
 Cooling System
• General
– LLC is used for engine coolant
– The radiator is made by copper

Air Relief
Valve

Copper
Radiator
Engine
 Cooling System
• General
– Air Relief valve is provided for better serviceability
Air Relief
Drain Cock Valve
(Engine Block)
Engine
 Fuel System
• General
• Fuel return less system is used to reduce evaporative emissions

Pulsation
Damper

4 Holes Injectors

Pressure Regulator

Filter
Quick connector on pipes

Pump
Mesin
 Sistem Bahan Bakar
–Valve untuk mencegah aliran balik digunakan untuk mencegah bahan
bakar menyemprot saat kesalahan mengisi bensin
–Mesin EJ-DE tidak mempunyai separator

Cut Off
Fuel Valve
Inlet Depan

Saat membuka

Balve pencegah aliran

balik Kapasitas
Tanda tangki 45 liter

*Tanda: K3-DE  “1”

EJ-DE  “2”
Mesin
 Sistem Bahan Bakar
EFI-T (no. 12)
• Pompa Bensin DLC 3
– Petunjuk

1. Dengan terminal EFI-T

dihubungkan ke GND, pompa
kerja 8 detik saat kunci
E (no. 4)
kontak ON
(Mesin tidak di start)

1. Dengan terminal EFI-T tidak

dihubungkan ke GND, pompa
ON
kerja 2 detik saat kunci
kontak ON
(Mesin tidak di start)
Engine
 Ignition System
• DIS (Direct Ignition System)
– DIS, provides 2 coils, one for two cylinders
– 2nd and 3rd cylinder, 1st and 4th cylinder
1st and 4th

DENSO NGK
K2OPR-U BKRGE
Gap 0.8 mm 0.8 mm
Width
2nd and 3rd Across 16 mm 16 mm
Flats
Mesin
 Sistem Pengapian (EJ-DE)
• DLI (Distributor Less Ignition)
– DLI, menggunakan 1 coil untuk setiap silinder

16 mm

DENSO NGK
K216PR-U11 BKR5E-11
Gap 1.1 mm 1.1 mm
Dengan
Ignition Coil dgn Igniter Across 16 mm 16 mm
Flats
Engine
 Engine Control System ( K3-DE )
• Components
Combination Meter
(Vehicle Speed Sensor)

Relay Block

Fuel
Pump
DLC 3

Manifold
Pressure Sensor

Variable
Resistor Engine ECU
Engine
 Engine Control System ( K3-DE )
• Components Throttle
Position Sensor Ignition Coil
Stepper Motor with Igniter
Type ISC

Camshaft
Position
Injector Sensor

Water Temp.
Sensor
Knock
Sensor

Crankshaft
Position
Sensor
Mesin
 Engine Control System (EJ-DE)
• Komponen ISC tipe
Stepper Motor

Throttle Position
Sensor

Manifold
Pressure Sensor
Camshaft
Position Sensor
Injector

Water Temp.
Knock Sensor Sensor

Crankshaft
position sensor Ignition Coil
with Igniter
Mesin
 Engine Control System
• Komponen
Komponen K3-DE EJ-DE
Engine ECU 16 Bit 
Pressure Sensor D-Type 
Crank Position Sensor
Tipe Pick-up coil (36-6) 
(Gigi Rotor)
Knock Sensor Built-in Piezoelectric 
Throttle Position Sensor Tipe Linear 
Injector Tipe 4 Hole 
Cam Position Sensor Tipe Pick-up coil 
Water Temp. Sensor Tipe Thermistor 
Ignition coil DLI 
Vehicle Speed Sensor Tipe Reed Switch 
Engine
 Engine Control System
• Idle Speed Control
– 2 coil stepper motor ISC is used for high control
accuracy on idle speed

Stepper Motor Type ISC

Engine
 Engine Control System
• Air Conditioner Cut Control
When the following condition is
satisfied, A/C is cut:

•By coolant temperature

– When coolant temperature above
set value (107ﾟC)

When at least one of the conditions is

satisfied, A/C is cut:

• When throttle valve opening degree

exceeds set value by vehicle speed
• When throttle valve opening degree
becomes set value or more
Engine
 Engine Control System
• VF Monitor Function
– The VF terminal voltage shows if there is
abnormality found by the diagnosis

DLC3
SST: 09843-18040 EFI-T
VF

E
V VF and E Voltage
•Ignition Switch ON 5V  Normal
•Do not depress accelerator pedal
0V  Abnormal
Engine
 Engine Control System
• Diagnosis Trouble Code
– DTC list which are different
from other TOYOTA DTC
Other
DTC No. Detection Item
TOYOTA DTC
42 22 Water Temperature Sensor Malfunction
18 52 Knock Sensor Circuit Malfunction
14 12 Camshaft Position Sensor Circuit Malfunction
52 42 Vehicle Speed Sensor Circuit Malfunction
71 33 Idle Speed Control System Malfunction
75 18 VVT Sensor Circuit Range/Performance Problem
51 - Switch Signal Circuit Malfunction
44 - A/C Evaporator Temp. Sensor Circuit Malfunction
Engine
 Engine Control System
• Fail-safe
DTC No. Detected Item Fail-safe Operation

- Pressure
signal is set to the value determined
by throttle opening angle, engine speed and
Pressure sensor open
31 ISC opening angle
or short circuit
- Fuel will be cut when idle switch is off and
engine rpm exceeds 3500 rpm.

Water temp. signal - The value is set to 79ﾟ C (inside ECU)

42
open or short circuit - Radiator fan will be turned ON

Throttle signal open

41 - Throttle signal is set to 20ﾟ (inside ECU)
or short circuit

Knock sensor open or

18 - Ignition timing is retarded
short circuit
Engine
 Engine Control System
• Fail-safe
DTC No. Detected Item Fail-safe Operation

- ISC drive is prohibited

ISC drive signal open - Fuel cut occurs and ignitiontiming is retarded
71
or short circuit according to throttle opening angle and ISC
position at the time of failure

A/F adjuster signal -A/F signal is set to constant value of 2.5 Volt
29
open or short circuit (inside ECU)

Evaporator
temperature sensor
44 open or short circuit -Air Conditioner will be cut
for more than certain
length of time
Chassis
 Clutch
• General
– Clutch system requires inspection and adjustment
of the pedal free play every 1 year or 10,000 km
Clutch Adjust Nut
Cable
Clutch
Pedal

Grommet
Chassis
 Transmisi Manual
• Spesifikasi

Tipe Transmisi M5S-C9 M5S-B9

Tipe Mesin K3-DE EJ-DE
1st 3.769 
2nd 2.045 
Perbandingan 3rd 1.376 1.457
Gigi 4th 1.000 
5th 0.838 
Mundur 4.128 
Kapasitas Oli (Liter) 1.2 
Viskositas Oli SAE 75W-90 
Grade Oli API GL-4 
Berat Kering (Kg) 23.2 
Chassis
 M5S-C9 Manual Transmission

Filler
Plug

Drain
Plug

Mass Damper
Chassis
 Rear Differential
• General
 Rear Differential
• General Specifications

Gear Ratio 5.125

Ring Gear Size

180
(mm)
Oil Capacity
1.6
(Liter)

Oil Viscosity SAE80W-90

Oil Grade API GL-5

Oil Type Hypoid

Chassis
 Suspension
• General

MacPherson strut
type independent
suspension

4 link coil spring with the

lateral rod type rigid axle
suspension
Chassis
 Brake
Lever type
• General PKB

9 in. Single
Booster

P&B
Valve

Leading-
Trailing Drum

Solid Disc
(for 13 in.)
Chassis
 Spare Tire Lock Bolt
Body Electrical
 Lighting
• Front Light Parking Hi/Lo Turn Signal
Light Beam Light

Fog Light (G Grade)

Body Electrical
 Lighting
• Rear Light
High Mount Stop Lamp (G Grade) Turn Signal
Light

Back-up
Light

Tail & Stop

Light

License Plate Light

Body Electrical
 Combination Switch
• Installation
– An independent construction make serviceability
has been improved

Wiper and Hook

Washer Switch

Light Control
Switch

Steering Column
Bracket
Body Electrical E : Single Cooler
 Cooler System G : Double Cooler
• Manual Cooler

Front Cooler Rear Cooler

Body Electrical
 Power Window and Door Lock
• General
– Power window* and door lock have been
adopted as standard equipment
Door Lock Switch

* Auto Power Window: Driver’s Only

Body Electrical
 Outside Rear View Mirror
• General
– Electrical Remote Control mirrors are used
(G Grade Only)