ignition TOYOTA AVENSIS 2003 Service User Guide

022J8±01
±
PREPARATION IGNITION
02±23
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION
PREPARATION
SST
09249±63010Torque Wrench AdaptorCRANKSHAFT POSITION SENSOR
(1AZ±FE/1AZ±FSE)
Recomended Tools
09082±00040TOYOTA Electrical TesterIGNITION SYSTEM(1AZ±FE)
IGNITION SYSTEM(1AZ±FSE)
IGNITION SYSTEM
(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetIGNITION SYSTEM(1AZ±FE)
IGNITION SYSTEM(1AZ±FSE)
IGNITION SYSTEM
(1ZZ±FE/3ZZ±FE)
09200±00010Engine Adjust KitIGNITION SYSTEM(1AZ±FE)
IGNITION SYSTEM(1AZ±FSE)
IGNITION SYSTEM
(1ZZ±FE/3ZZ±FE)
(09857±00031)Spark Plug Gap GaugeIGNITION SYSTEM(1AZ±FE)
IGNITION SYSTEM(1AZ±FSE)
IGNITION SYSTEM
(1ZZ±FE/3ZZ±FE)
Equipment
Ohmmeter
Service Wire Harness
Torque wrench
http://vnx.su

022L3±01
±
PREPARATION VEHICLE CONTROL SYSTEM
02±63
AVENSIS REPAIR MANUAL (RM1018E)
VEHICLE CONTROL SYSTEM
PREPARATION
Recomended Tools
09082±00040TOYOTA Electrical TesterIGNITION OR STARTER SWITCH
ASSY
09082±00050TOYOTA Electrical Tester SetIGNITION OR STARTER SWITCH
ASSY
http://vnx.su

031DY±01
03±4
±
SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE CONTROL SYSTEM
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Power steering oil pressure switch
Voltage EMPS ± E2 Not spin the steering wheel at engine idling
Spin the steering wheel at engine idling
8 to 14 V
0 to 1.5 V
Idle air control valve
Movement Ignition switch ON
Half open  fully close  fully open  half open
Mass air flow meter
Resistance 4 (THA) ± 5 (E2)
at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
13.6 to 18.4 k

2.21 to .69 k

0.49 to 0.67 k

Camshaft timing oil control valve assy
Resistance at 20
C (68
F)
6.9 to 7.9

Throttle position sensor
Resistance VC ± E2
2.5 to 6.0 k

E.F.I. Engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k

0.310 to 0.326 k

Knock control sensor
Resistance Approx. 20
C (68
F)
120 to 280 k

1AZ±FE/1AZ±FSE:
Power steering oil pressure switch
Voltage PSW ± E2
Not spin the steering wheel at engine idling
Spin the steering wheel at engine idling
9 to 14 V
0 to 3 V
Idle air control valve
Movement Ignition switch ON
Half open  fully close  fully open  half open
Throttle body assy (1AZ±FSE)
Throttle valve opening percentage
Idle speed
60 % or more
700  50 rpm
Accelerator pedal position sensor (1AZ±FSE)
Voltage ACCEL POS Released
Depress
ACCEL POS #2 Released Depress
0.5 to 1.1 V
2.6 to 4.5 V
1.2 to 2.0 V
3.4 to 5.3 V
Mass air flow meter
Resistance 4 (THA) ± 5 (E2) at ±20
C (±4
F)
at 20
C (68
F)
at 60
C (140
F)
13.6 to 18.4 k

2.21 to .69 k

0.49 to 0.67 k

Camshaft timing oil control valve assy
Resistance at 20
C (68
F)
6.9 to 7.9

Throttle position sensor (1AZ±FE)
Resistance VC ± E2
2.5 to 5.0 k

Throttle body assy (1AZ±FSE)
Resistance 2 (M+) ± 1 (M±)
0.3 to 100
at 20
C (68
F)
E.F.I. Engine coolant temperature sensor
Resistance Approx. 20
C (68
F)
Approx. 80
C (176
F)
2.32 to 2.59 k

0.310 to 0.326 k

Knock control sensor
Resistance Approx. 20
C (68
F)
120 to 280 k

http://vnx.su

031H1±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±13
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE MECHANICAL
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Ignition timingw/ Terminal TC and CG of DLC3 connected
W/ Terminal TC and CG of DLC3 disconnected8 to 12
BTDC
10 to 18
BTDC (1ZZ±FE)
3.5 to 11.5
BTDC (3ZZ±FE)
Idle speed600 to 700 rpm
Compression
Compression pressure
Minimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf
cm2, 189 psi)
1,000 kPa (10.2 kgf
cm2, 145 psi)
100 kPa (1.0 kgf
cm2, 14 psi)
Cylinder head set bolt Length Standard
Maximum146.8 to 148.2 mm (5.780 to 5.835 in.)
148.5 mm (5.846 in.)
Valve clearance (Cold)
No. 1 Cylinder TDC/Compression Intake Exhaust
No. 4 Cylinder TDC/Compression Intake Exhaust
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
0.15 to 0.25 mm (0.0059 to 0.0098 in.)
0.25 to 0.35 mm (0.0098 to 0.0138 in.)
1AZ±FE:
Battery specific gravityat 20
C (68
F)1.25 to 1.29
Ignition timing w/ Terminals TC and CG of DLC3 connected
w/ Terminals TC and CG of DLC3 disconnected8 to 12
BTDC
5 to 15
BTDC
Idle speed650 to 750 rpm
Compression
Compression pressureMinimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf/cm2, 189 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 14 psi)
Cylinder head set bolt
Bolt length Standard Maximum
161.3 to 162.3 mm (6.350 to 6.390 in.)
164.2 mm (6.465 in.)
Valve clearance
Intake (Cold)
Exhaust
0.19 to 0.29 mm (0.0075 to 0.0114 in.)
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
1AZ±FSE:
Battery specific gravityat 20
C (68
F)1.25 to 1.29
Ignition timing w/ Terminals TC and CG of DLC3 connected
w/ Terminals TC and CG of DLC3 disconnected8 to 12
BTDC
5 to 23
BTDC
Idle speed625 to 725 rpm
Compression
Compression pressureMinimum pressure
Difference between each cylinder
1,300 kPa (13.3 kgf/cm2, 189 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 14 psi)
Cylinder head set bolt
Bolt length Standard Maximum
161.3 to 162.3 mm (6.350 to 6.390 in.)
164.2 mm (6.465 in.)
Valve clearance
Intake (Cold)
Exhaust
0.19 to 0.29 mm (0.0075 to 0.0114 in.)
0.30 to 0.40 mm (0.0118 to 0.0157 in.)
http://vnx.su

031H2±01
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±15
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Camshaft bearing cap No. 3 x Cylinder head sub±assy1313310
Camshaft bearing cap No. 1 x Cylinder head sub±assy2323517
Camshaft timing gear or sprocket x Camshaft No. 25455140
Chain tensioner assy No. 1 x Timing chain or belt cover sub±assy9.09280 in.
lbf
V±ribbed belt tensioner assy x Cylinder block sub±assy6970451
V±ribbed belt tensioner assy x Cylinder head sub±assy2929621
Engine mounting insulator RH x Body5253038
Engine mounting insulator RH x Transverse engine engine mounting bracket5253038
Cylinder head cover sub±assy x Cylinder head sub±assy A
B11
9.011 2 928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Ignition coil assy x Cylinder head cover sub±assy9.09280 in.
lbf
Engine wire x Cylinder head cover sub±assy9.09280 in.
lbf
Cylinder head cover No. 2 x Cylinder head cover sub±assy7.07162 in.
lbf
Engine hanger x Cylinder head sub±assy3838728
Radio setting condenser x Cylinder head sub±assy101027
Engine coolant temperature sensor x Cylinder head sub±assy2020415
Exhaust manifold x Cylinder head sub±assy3737727
Exhaust manifold heat insulator No. 1 x Exhaust manifold Bolt
Nut18
12184
12213 9
Manifold stay No. 2 x Exhaust manifold4950036
Manifold stay No. 2 x Cylinder block sub±assy4950036
Manifold stay x Exhaust manifold A4950036
Manifold stay x Cylinder block sub±assyB3737727
Transverse engine engine mounting bracket x Timing chain or belt cover
sub±assy4747935
V±ribbed idler assy No.1 x Cylinder block sub±assy39.240029
Knock sensor x Cylinder block sub±assy2020415
Crankshaft position sensor x Timing chain or belt cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Water inlet x Cylinder block sub±assy1111 28
Water by±pass pipe No. 1 x Cylinder block sub±assy9.09280 in.
lbf
Water by±pass pipe No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Oil level gage guide x Water by±pass pipe No. 11313310
Intake manifold x Cylinder head sub±assy3030622
Flywheel sub±assy x Crankshaft 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Drive plate & ring gear sub±assy x Crankshaft8889765
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front5253038
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Transverse engine engine mounting bracket LH x Transverse engine engine
mounting insulator LH8081659
Transverse engine engine mounting bracket RH x Transverse engine engine
mounting insulator RH5253038
Front suspension crossmember sub±assy x Body A
B45
133459
1,35633
98
Front suspension member brace x Body Bolt A
Bolt B133 801,356 81698
59
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03±16
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Floor panel brace front x Body3030622
Battery carrier x Body12.81319
Battery x Body5.05144 in.
lbf
Air cleaner case x Body5.05144 in.
lbf
Air cleaner case x Transverse engine engine mounting bracket LH5.05144 in.
lbf
Radiator support upper x Body1919414
Front wheel RH & LH x Front axle hub sub±assy RH & LH1031,05076
Camshaft timing gear assy x Camshaft5455140
Chain tensioner slipper x Cylinder block sub±assy1919414
Timing chain or belt cover sub±assy x Cylinder head sub±assy1313310
Timing chain or belt cover sub±assy x Cylinder block sub±assy M6
M813
19133
19410
14
Crankshaft pulley x Crankshaft1381,407102
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block sub±assy9.09280 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Intake manifold x Cylinder head3030622
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
http://vnx.su

03±18
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E) Part Tightened
ft
lbf
kgf
cm
N
m
Knock sensor x Cylinder block2020815
Engine oil pressure switch assy x Cylinder head1515311
Water by±pass pipe No.1 x Cylinder block9.09280 in.
lbf
Drive shaft bearing bracket x Cylinder block5455140
Oil level gauge guide x Cylinder block9.09280 in.
lbf
V±ribbed belt tensioner assy x Timing chain cover6060744
Ignition coil assy x Cylinder head9.09280 in.
lbf
Water inlet x Cylinder block9.09280 in.
lbf
Exhaust manifold converter x Cylinder head3737827
Exhaust manifold stay x Exhaust manifold converter4444932
Manifold converter insulator No. 1 x Exhaust manifold converter121229
Surge tank stay No. 1 x Intake manifold2121015
Intake manifold x Cylinder head3030622
Throttle Body bracket x Throttle body2121015
Fly wheel (M/T) x Crank shaft1301,32796
Drive plate & ring gear (A/T) x Crankshaft981,00072
Transverse engine engine mounting bracket front x Transverse engine en-
gine mounting insulator front8788764
Transverse engine engine mounting bracket rear x Transverse engine engine
mounting insulator rear8788764
Front suspension cross member sub±assy front x Body Front
Rear45
133459
1,35633
98
Front suspension brace RH x Frame Bolt A
Bolt B133 801,356 81698
59
Front suspension brace LH x Frame Bolt A
Bolt B133
801,356 81698
59
Transverse engine engine mounting insulator LH x Engine mounting bracket
LH8788764
Transverse engine engine mounting insulator RH x Engine mounting bracket
RH5253038
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulator A B
52
11 3530
1,15238
83
Clutch release cylinder x manual transaxle Bolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket x Body LHD steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder block2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block 1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
http://vnx.su

031E4±01
03±30
±
SERVICE SPECIFICATIONS IGNITION
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Spark plug
Recommended spark plug DENSO made NGK made
Electrode gap K16R±U11, BKR5EYA11
K16R±U11
BKR5EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance ColdHot
1,630 to 2,740

2,065 to 3,225

1AZ±FE:
Spark plug
Recommended spark plug DENSO madeNGK made
Electrode gap K20R±U11, BKR6EYA11
K20R±U11
BKR6EYA11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance Cold Hot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance ColdHot
985 to 1,600

1,265 to 1,890

1AZ±FSE:
Spark plug
Recommended spark plug DENSO made
Electrode gap SK20BR11
SK20BR11
1.0 to 1.1 mm (0.039 to 0.043 in.)
Camshaft position sensor
Resistance ColdHot
835 to 1,400

1,060 to 1,645

Crankshaft position sensor
Resistance ColdHot
985 to 1,600

1,265 to 1,890

http://vnx.su

031E5±01
±
SERVICE SPECIFICATIONS IGNITION
03±31
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1818413
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf
Cord clamp x Timing chain cover sub±assy9.09280 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Spark plug x Cylinder head1919414
Ignition coil (with igniter) x Cylinder head cover9.09280 in.
lbf
Camshaft position sensor x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft position sensor x Timing chain cover sub±assy9.09280 in.
lbf
http://vnx.su

031H6±01
03±28
±
SERVICE SPECIFICATIONS LUBRICATION
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan3737727
Oil pump x Cylinder block9.09280 in.
lbf
1AZ±FE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.
lbf
Oil pan sub±assy x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket RH x Body LHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Engine x wire7.07162 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Return tube x Body8.08271 in.
lbf
Ignition coil assy x Cylinder head cover9.09280 in.
lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.
lbf
Front wheel RH1031,05076
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Oil pressure switch x Cylinder head1515311
Oil pan drain plug x Oil pan2525018
Oil pump x Cylinder block1919515
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain vibration damper No.1 x Cylinder block9.09280 in.
lbf
Oil pan sub±assy x Cylinder block9.09280 in.
lbf
Transverse engine engine mounting insulator x Cylinder block5253038
Engine service cover bracket RH x Body RHD steering position type9.09280 in.
lbf
Cooler bracket RH x Body LHD steering position type9.09280 in.
lbf
Engine x wire7.07162 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Cooler refrigerant suction hose No. 1 x cooler bracket No, 1
LHD steering position type9.09280 in.
lbf
Return tube x Body8.08271 in.
lbf
Ignition coil assy x Cylinder head cover9.09280 in.
lbf
Vane pump x Cylinder block3737727
Engine cover sub±assy x Cylinder block7.07162 in.
lbf
Front wheel RH1031,05076
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Oil drain plug x Oil pan sub±assy No. 23435025
Oil pump x Cylinder block3132023
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