Insulator TOYOTA AVENSIS 2003 Service Repair Manual

1807N±01
A50033
P03783
P03792
IG0147
Ohmmeter
Ground
±
IGNITION IGNITION SYSTEM (1AZ±FE)
18±9
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT SPARK PLUG (EXCEPT EUROPE)
(a) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode
with a spark plug cleaner then dry it.
Air pressure: Below 588 kPa (6kg/cm
2, 85 psi)
Duration: 20 seconds or less
(b) Check the spark plug for any damage on its thread and insulator damage.
If there is damage, replace the spark plug. Recommended spark plug:
DENSO madeK20R±U11
NGK madeBKR6EYA11
(c) Adjust electrode gap.Electrode gap: 1.0 to 1.1 mm (0.039 to 0.043 in.)
2. INSPECT SPARK PLUG (FOR EUROPE)
NOTICE:

Do not use a wire brush for cleaning.

Do not attempt to adjust the electrode gap of a used
spark plug.

Spark plug should be replaced every 100,000 km
(60,000 miles).
(a) Check the electrode. (1) Using an ohmmeter, measure the insulation resis-tance.
Correct insulation resistance: 10 M
or more
If the resistance is less then the specified valve, proceed to step
(d).
HINT:
If the ohmmeter is not available, perform the following alterna-
tive inspection. This provides also fairly accurate results.
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B01301
IG0316
B02101
1.1 mm
B62019
18±10
±
IGNITION IGNITION SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Alternative inspection: (1) Quickly accelerate the engine to 4,000 rpm 5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (C).
(6) Reinstall the spark plug.
(c) Check the spark plug for any damage on its thread and insulator.
If there is damage, replace the spark plug. Recommended spark plug:
DENSO madeSK20R11
NGK madeIFR6A11
(d) Check the spark plug electrode gap.Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug:
1.0 to 1.1 mm (0.039 to 0.043 in.)
(e) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode
with a spark plug cleaner then dry it. Air pressure: Blow 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
3. INSPECT CAMSHAFT POSITION SENSOR
(a) Using an ohmmeter, measure the resistance between the terminals. RESISTANCE:
835 to 1,400  at cold
1,060 to 1,645 at hot
NOTICE:
ºColdº and ºHotº mean the temperature of the coils themselve\
s.ºColdº is from ± 10
C (14
F) to 50

C (122
F) and ºHotº is from 50
C (122
F) to 100
C (212
F).
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1807R±01
IG0147
Ohmmeter
Ground
A78638
A78639
18±14
±
IGNITION IGNITION SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT SPARK PLUG
NOTICE:

Do not use a wire brush for cleaning.

Do not attempt to adjust the electrode gap of a used
spark plug.

Spark plug should be replaced every 100,000 km
(60,000 miles).
(a) Check the electrode. (1) Using an ohmmeter, measure the insulation resis-
tance.
Correct insulation resistance: 10 M
or more
If the resistance is less then the specified value, proceed to step
(d).
HINT:
If the ohmmeter is not available, do the following inspection
instead.
(b) Alternative inspection: (1) Quickly accelerate the engine to 4,000 rpm 5 times.
(2) Remove the spark plug.
(3) Visually check the spark plug.
If a kink or twist as shown in the illustration on the left is found
on the spark plug, replace it with a new one.
(4) If the electrode is dry...OK.
(5) If the electrode is wet...Proceed to step (e).
(6) Reinstall the spark plug.
(c) Check the spark plug for any damage on its thread and insulator.
If there is damage, replace the spark plug.
Recommended spark plug:
DENSO madeSK20BR11
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1807P±01
A50033
P03783
P03792
±
IGNITION IGNITION SYSTEM (1ZZ±FE/3ZZ±FE)
18±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT SPARK PLUG
(a) Clean the spark plugs.
If the electrode has traces of wet carbon, clean the electrode
with a spark plug cleaner then dry it.
Air pressure: Below 588 kPa (6kg/cm
2, 85 psi)
Duration: 20 seconds or less
(b) Check the spark plug for any damage on its thread and insulator damage.
If there is damage, replace the spark plug. Recommended spark plug:
DENSO madeK16R±U11
NGK madeBKR5EYA11
(c) Adjust electrode gap.Electrode gap: 1.0 to 1.1 mm (0.039 to 0.043 in.)
2. INSPECT CAMSHAFT POSITION SENSOR
(a) Using an ohmmeter, measure the resistance between the terminals. RESISTANCE:
835 to 1,400  at cold
1,060 to 1,645 at hot
NOTICE:
ºColdº and ºHotº mean the temperature of the coils themselve\
s.ºColdº is from ± 10
C (14
F) to 50

C (122
F) and ºHotº is from 50
C (122
F) to 100
C (212
F).
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28mm
F44963
F40270
SST
F08624
SST
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
26±11
AVENSIS REPAIR MANUAL (RM1018E)
4. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of
the shock absorber and secure it in a vise.
5. REMOVE FRONT SUSPENSION SUPPORT DUST COVER LH 6. REMOVE FRONT SUPPORT TO FRONT SHOCKABSORBER LH NUT
(a) Using SST, compress the coil spring. SST 09727±30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Remove the front suspension support dust cover from the
suspension support.
(c) Using SST to hold the spring seat, remove the nut. SST 09729±22031
7. REMOVE FRONT SUSPENSION SUPPORT SUB±ASSY LH
8. REMOVE FRONT SUSPENSION SUPPORT LH DUST SEAL
9. REMOVE FRONT COIL SPRING SEAT UPPER LH
10. REMOVE FRONT COIL SPRING INSULATOR UPPER LH
11. REMOVE FRONT COIL SPRING LH
12. REMOVE FRONT SPRING BUMPER LH
13. REMOVE FRONT COIL SPRING INSULATOR LOWER LH
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C80884
F40271
SST
F13692
OutsideOutside
F40272
Outside
26±12
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
14. INSPECT SHOCK ABSORBER ASSY FRONT LH
(a) Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound
during operation.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When disposing of the shock absorber, see DISPOSAL on
page 26±15.
15. INSTALL FRONT COIL SPRING INSULATOR LOWER LH
HINT:
Fit the front coil spring insulator lower into the gap of the shock abso\
rber.
(a) Install the front coil spring insulator lower onto the shock absorber.
16. INSTALL FRONT SPRING BUMPER LH
(a) Install the spring bumper to the piston rod.
17. INSTALL FRONT COIL SPRING LH
(a) Using SST, compress the coil spring.SST 09727±30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the front coil
spring insulator lower LH.
18. INSTALL FRONT COIL SPRING INSULATOR UPPER LH
(a) Install the upper insulator as shown in the illustration.
19. INSTALL FRONT COIL SPRING SEAT UPPER LH
(a) Install the spring seat to the shock absorber with the mark facing to the outside of the vehicle.
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260DP±01
F44614
Front Shock Absorber with Coil Spring
Front Stabilizer Link Assy LH
47 (479, 35)
220 (2,240, 162)
74 (755, 55)
19 (194, 14)
Speed Sensor
Front LH
Front Flexible Hose
Front Suspension Support Dust Cover LH
Front Suspension Support Sub±assy LH
Front Suspension
Support LH Dust Seal
Front Coil Spring
Seat Upper LH
Front Axle Assy
Front Coil Spring Insulator Upper LH
Front Coil Spring LH
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Front Spring
Bumper LH
Front Coil
Spring Insulator
Lower LH
Shock Absorber
Assy Front LH
39 (398, 29)


26±2
±
FRONT SUSPENSION FRONT SUSPENSION
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SUSPENSION
COMPONENTS
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F44615
Rack & Pinion Power
Steering Gear Assy
49 (500, 36)
Tie Rod End Sub±assy LH
Front Stabilizer Link Assy RH
Transverse Engine
Engine Mounting Insulator
Front Stabilizer Link Assy LH
Front Suspension
Crossmember Sub±assy
Front Suspension
Member Body Mounting
Stopper FR
133 (1,360, 98)
137 (1,400, 101)
Body Mounting Stopper Rear
52 (530, 38)
80 (816, 59)
74 (755, 55)
Front Suspension
Member Brace
Rear LH
80 (816, 59)
133 (1,360, 98)
Cotter Pin
49 (500, 36)
89 (908, 66)
Front Suspension Arm
Sub±assy Lower No.1 LH
80 (816, 59)
133 (1,360, 98)
80 (816, 59)
Front Suspension
Member Brace
Rear RH
133 (1,360, 98)
137 (1,400, 101)
N
m (kgf
cm, ft
lbf) : Specified torque

Nblt

Non±reusable part

Engine Mounting Member
Sub±assy Center
96 (979, 71)
±
FRONT SUSPENSION FRONT SUSPENSION
26±3
AVENSIS REPAIR MANUAL (RM1018E)
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C95317
C86742
C87504
C95318
±
FRONT SUSPENSION FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1
LH (ATM)26±17
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE FRONT SUSPENSION MEMBER B RACE
REAR LH
(a) Support the front suspension crossmember sub±assy
with a transmission jack.
(b) Remove the 4 bolts and front suspension member brace rear LH.
(c) Remove the front suspension member body mounting
stopper rear from the front suspension member brace
rear LH.
11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
HINT:
Remove the RH side by the same procedures as the LH side.
12. SEPARATE FRONT SUSPENSION CROSSMEMBERSUB±ASSY
(a) w/ HID: Disconnect the height control sensor (Front) connector.
(b) Remove the 3 bolts and 3 nuts, disconnect the transverse
engine engine mounting insulator and engine mounting
member sub±assy center from the front suspension
crossmember sub±assy.
(c) Remove the 2 nuts and 2 front suspension member body mounting stoppers front.
(d) Lower the transmission jack, remove the front suspension crossmember sub±assy.
13. REMOVE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH
(a) Remove the 2 bolts, nut and lower suspension arm sub±
assy lower No.1 LH from the front suspension crossmem-
ber sub±assy.
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C95735SST

C95736




G24415
Rear shock
absorber
cushion
No.1 Rear
suspension
support
assy LH
G23869
F40128
SST
27±10
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
15. REMOVE SHOCK ABSORBER ASSY REAR LH
(a) Using SST, compress the coil rear spring. SST 09727±30021 (09727±00010, 09727±00021,
09727±00031)
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Using a 6 mm hexagon wrench to hold the piston rod, re- move the nut.
(c) Remove the rear shock absorber cushion washer No.1.
(d) Remove the rear suspension support assy LH.
(e) Remove the rear spring front bracket sub±assy LH.
(f) Remove the rear shock absorber cushion No.1.
(g) Remove the rear spring bumper No.1 LH.
(h) Remove the rear coil spring insulator upper LH.
(i) Remove the coil rear spring.
16. INSPECT SHOCK ABSORBER ASSY REAR LH
(a) Compress and extend the shock absorber rod and check for unusual resistance or unusual sound during the op-
eration.
If there is any malfunction, replace the shock absorber assy
rear LH with a new one.
17. INSTALL SHOCK ABSORBER ASSY REAR LH
(a) Using SST, compress the coil rear spring. SST 09727±30021 (09727±00010, 09727±00021,
09727±00031)
NOTICE:
Do not use an impact wrench. It will damage the SST.
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