TOYOTA AVENSIS 2003 Service Repair Manual

1807I±01
A78482
±
IGNITIONCAMSHAFT POSITION SENSOR(1ZZ±FE/3ZZ±FE)
18±5
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT POSITION SENSOR(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
2.REMOVE CYLINDER HEAD COVER NO.2 (See page 10±9)
3.REMOVE CAMSHAFT POSITION SENSOR
(a)Disconnect the camshaft position sensor connector.
(b)Remove the bolt, and then remove the camshaft positionsensor.
4.INSTALL CAMSHAFT POSITION SENSOR
(a)Apply a light coat of engine oil to the O±ring on the camshaft positi\
on sensor.
(b)Install the camshaft position sensor with the bolt. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(c)Connect the camshaft position sensor connector.
5.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
6. INSTALL RADIATOR SUPPORT OPENING COVER
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1807L±01
A77896
(a)(b)
(c)
(d)
±
IGNITIONCRANKSHAFT POSITION
SENSOR(1AZ±FE/1AZ±FSE)18±17
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT POSITION SENSOR(1AZ±FE/1AZ±FSE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER LH (See page 19±20)
2.REMOVE ENGINE UNDER COVER RH (See page 19±20)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
5.REMOVE FAN AND GENERATOR V BELT
6.REMOVE GENERATOR ASSY (See page 19±20)
SST09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
7.REMOVE CRANKSHAFT POSITION SENSOR
(a)Disconnect the crankshaft position sensor connector.
(b)Remove the wire harness of the crankshaft position sen-sor from the wire harness clamp bracket.
(c)Remove the connector clamp.
(d)Remove the wire harness clamp.
(e)Remove the bolt, and then remove the crankshaft posi-
tion sensor.
8.INSTALL CRANKSHAFT POSITION SENSOR
(a)Apply a light coat of engine oil to the O±ring on the crankshaft posi\
tion sensor.
(b)Install the crankshaft position sensor with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
(c)Install the wire harness clamp.
(d)Install the connector clamp.
(e)Install the wire harness of the crankshaft position sensor to the the wi\
re harness clamp bracket.
(f)Connect the crankshaft position sensor connector.
9.INSTALL GENERATOR ASSY (See page 19±20)
10. INSTALL FAN AND GENERATOR V BELT SST 09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
11. INSTALL ENGINE ROOM COVER SIDE
12. INSTALL RADIATOR SUPPORT OPENING COVER
13. INSTALL ENGINE UNDER COVER RH
14. INSTALL ENGINE UNDER COVER LH
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1807J±01
A78483
(a)
(b)
A78484
(f)
(e)(d)
18±6
±
IGNITIONCRANKSHAFT POSITION SENSOR(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT POSITION SENSOR(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER LH (See page 19±20)
2.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 10±17)
3.REMOVE ENGINE UNDER COVER RH (See page 19±20)
4.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
5.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
6.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
7.REMOVE GENERATOR ASSY (See page 19±7) 8.REMOVE CRANKSHAFT POSITION SENSOR
(a)Disconnect the crankshaft position sensor connector.
(b)Remove the connector clamp.
(c)Remove the 2 bolts, and then remove the crankshaft posi-tion sensor.
(d)Remove the cord clamp from the crankshaft position sen- sor.
9.INSTALL CRANKSHAFT POSITION SENSOR
(a)Install the cord clamp to the crankshaft position sensor.
(b)Apply a light coat of engine oil on the O±ring of the crank- shaft position sensor.
(c)Install the crankshaft position sensor with the 2 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(d)Install the wire harness as shown in the illustration.
(e)Install the connector clamp.
(f)Connect the crankshaft position sensor connector.
10.INSTALL GENERATOR ASSY (See page 19±7)
11.INSTALL FAN AND GENERATOR V BELT (See page 14±5)
12. INSTALL ENGINE ROOM COVER SIDE
13. INSTALL RADIATOR SUPPORT OPENING COVER
14. INSTALL ENGINE UNDER COVER RH
15. INSTALL ENGINE UNDER COVER SUB±ASSY NO.1
16. INSTALL ENGINE UNDER COVER LH
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1807M±01
CHECK POWER SUPPLY TO IGNITION COIL WITHSENSOR (See page 18±9)
SPARK TEST
Replace crankshaft position sensor.
CHECK RESISTANCE OF CAMSHAFT POSITION
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL WITH IGNITER
Resistance: ColdHot
1,060 to 1,645

CHECK RESISTANCE OF CRANKSHAFT POSITION
Resistance: ColdHot
985 to 1,600
1,265 to 1,890

CHECK IGT SIGNAL FROM ECM
(See page 05±232)
REPAIR WIRING BETWEEN IGNITION COIL AND ECM Connect securely.
Check wiring between ignition switch to ignition coil with igniter.
Check ECM (See page 01±32)
NG
OK
OK
OK
OK NG
NG
NG
NG
NG
SENSOR (See page 18±9 )
835 to 1,400


IGNITER
CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER
AND PERFORM SPARK TEST AGAIN
OK
Replace ignition coil with igniter.
NG
OK
CONNECTOR
Replace camshaft position sensor.
±
IGNITIONIGNITION SYSTEM(1AZ±FE)
18±7
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION SYSTEM(1AZ±FE)
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean the temperature of the coils thems\
elves.ºColdº is from ±10C
(14F) to 50 C (122 F) and ºHotº is from 50 C (122 F) to 100 C (212 F).
1.INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
(a)Check for DTCs.
NOTICE:
If DTC is present, perform a troubleshooting in accordance with a proced\
ure for that DTC.
(b)Check that spark occurs. (1)Remove the cylinder head cover No. 1. (See page 14±106)
(2) Remove the ignition coils (with igniter).
(3) Using a 16mm (0.63 in) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil (with igniter) and connect the \
ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if spark occurs at each spark plug while engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil if it is given physical impact.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:
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18±8
±
IGNITION IGNITION SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(d) Install the ignition coil with igniter.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(e)Install the cylinder head cover No. 1. (See page 14±106 )
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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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±
IGNITION IGNITION SYSTEM (1AZ±FE)
18±11
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT CRANKSHAFT POSITION SENSOR
(a) Using an ohmmeter, measure the resistance between the terminals.
RESISTANCE:
985 to 1,600  at cold
1,265 to 1,890 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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1807Q±01
CHECK POWER SUPPLY TO IGNITION COIL WITHSENSOR (See page 18±14)
SPARK TEST
Replace crankshaft position sensor.
CHECK RESISTANCE OF CAMSHAFT POSITION
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL WITH IGNITER
Resistance: ColdHot
1,060 to 1,645

CHECK RESISTANCE OF CRANKSHAFT POSITION
Resistance: ColdHot
985 to 1,600
1,265 to 1,890

CHECK IGT SIGNAL FROM ECM
(See page 05±439)
REPAIR WIRING BETWEEN IGNITION COIL AND ECM Connect securely.
Check wiring between ignition switch to ignition coil with igniter.
Check ECM (See page 01±32)
NG
OK
OK
OK
OK NG
NG
NG
NG
NG
SENSOR (See page 18±14)
835 to 1,400


IGNITER
CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER
AND PERFORM SPARK TEST AGAIN
OK
Replace ignition coil with igniter.
NG
OK
CONNECTOR
Replace camshaft position sensor.
18±12
±
IGNITIONIGNITION SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
IGNITION SYSTEM(1AZ±FSE)
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in this section mean the temperature of the coils thems\
elves.ºColdº is from ±10C
(14F) to 50 C (122 F) and ºHotº is from 50 C (122 F) to 100 C (212 F).
1.INSPECT IGNITION COIL (WITH IGNITER) AND SPARK TEST
(a)Check for DTCs.
NOTICE:
If DTC is present, perform a troubleshooting in accordance with a proced\
ure for that DTC.
(b)Check that spark occurs. (1)Remove the cylinder head cover No. 1. (See page 14±186)
(2) Remove the ignition coils (with igniter).
(3) Using a 16mm (0.63 in) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil (with igniter) and connect the \
ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if spark occurs at each spark plug while engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil it is given physical impact.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:
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±
IGNITIONIGNITION SYSTEM(1AZ±FSE)
18±13
AVENSIS REPAIR MANUAL (RM1018E)
(c)Using a 16 mm (0.63 in.) plug wrench, install the spark plugs.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(d)Install the ignition coil with igniter.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
(e)Install the cylinder head cover No. 1. (See page 14±186)
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