2003 TOYOTA AVENSIS Spark plug

A62181
PlungerTurn
Push
A10085
A62182
Seal Packing
14±26
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(4) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released from the knock pin and the plunger springs out.
66. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Install the gasket to the cylinder head cover.
(b) Remove any old packing (FIPG) material.
(c) Apply seal packing to 2 locations as shown in the illustra- tion.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not put into engine oil 2 hours after installing.
(d) Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts
Uniformly tighten the bolts and nuts, in the several
passes.
Torque:
w/o washer 11 N
m (112 kgf
cm, 8 ft
lbf)
w/ washer 9.0 N
m (92 kgf
cm, 80 in
lbf)
67. INSTALL SPARK PLUG
(a) Using a spark lug wrench, install the 4 spark plugs. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
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0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock sub±assy x Cylinder block sub±assy\
2020415
Oil strainer sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan drain plug x Oil pan sub±assy3737727
Oil filter union x Cylinder block sub±assy3030622
Oil pump assy x Cylinder block sub±assy9.09280 in.
lbf
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Oil control valve filter x Cylinder head sub±assy3030622
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing gear or sprocket x Camshaft No. 25455140
Camshaft, Camshaft No. 2 x Cylinder head sub±assy Bearing cap No. 1
Bearing cap No. 323
13235
13317
10
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
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
Chain tensioner assy No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft pulley x Crankshaft1381,407102
Water pump assy x Cylinder block sub±assy1111 28
Water pump assy x Timing chain or belt cover sub±assy9.09280 in.
lbf
Cylinder head cover sub±assy x Cylinder head sub±assy w/o washer
w/ washer11
9.011 2 928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Spark plug x Cylinder head sub±assy2525518
Stud bolt
Timing chain or belt cover sub±assy x Cylinder head sub±assy
length 89 mm (3.50 in.)
length 53.5 mm (2.11 in.)
Cylinder head cover sub±assy x Cylinder head sub±assy
Intake manifold x Cylinder head sub±assy
Exhaust manifold x Cylinder head sub±assy
9.5
5.0
5.0
9.5
9.597
51
51
97
9784 in.
lbf
44 in.
lbf
44 in.
lbf
84 in.
lbf
84 in.
lbf
W/ Head taper screw plug No. 2 x Cylinder head sub±assy4444933
Crankshaft bearing cap sub±assy x Cylinder block sub±assy M10 1st
2nd3rd
M822
44
Turn 90
19224
449
Turn 90
19416
33
Turn 90
14
Connecting rod x Connecting rod cap 1st
2nd20
Turn 90
204
Turn 90
15
Turn 90

Stud bolt
Water by±pass pipe No. 1 x Cylinder block sub±assy
Water inlet x Cylinder block sub±assy
Oil strainer sub±assy x Cylinder block sub±assy
Oil pan sub±assy x Cylinder block sub±assy
Knock control sensor x Cylinder block sub±assy
5.0
5.0
5.0
5.0 1151
51
51
51
11 244 in.
lbf
44 in.
lbf
44 in.
lbf
44 in.
lbf
8
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0300P±02
±
SERVICE SPECIFICATIONS ENGINE MECHANICAL
03±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Cylinder block water drain cock sub±assy x Cylinder block sub±assy\
2020415
Oil strainer sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan sub±assy x Cylinder block sub±assy9.09280 in.
lbf
Oil pan drain plug x Oil pan sub±assy3737727
Oil filter union x Cylinder block sub±assy3030622
Oil pump assy x Cylinder block sub±assy9.09280 in.
lbf
Cylinder head sub±assy x Cylinder block sub±assy 1st
2nd49
Turn 90
500
Turn 90
36
Turn 90

Oil control valve filter x Cylinder head sub±assy3030622
Camshaft timing oil control valve assy x Cylinder head sub±assy9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing gear or sprocket x Camshaft No. 25455140
Camshaft, Camshaft No. 2 x Cylinder head sub±assy Bearing cap No. 1
Bearing cap No. 323
13235
13317
10
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
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
Chain tensioner assy No. 1 x Cylinder head sub±assy9.09280 in.
lbf
Crankshaft pulley x Crankshaft1381,407102
Water pump assy x Cylinder block sub±assy1111 28
Water pump assy x Timing chain or belt cover sub±assy9.09280 in.
lbf
Cylinder head cover sub±assy x Cylinder head sub±assy w/o washer
w/ washer11
9.011 2 928
80 in.
lbf
Cylinder head cover sub±assy x Timing chain or belt cover sub±assy1111 28
Spark plug x Cylinder head sub±assy2525518
Stud bolt
Timing chain or belt cover sub±assy x Cylinder head sub±assy
length 89 mm (3.50 in.)
length 53.5 mm (2.11 in.)
Cylinder head cover sub±assy x Cylinder head sub±assy
Intake manifold x Cylinder head sub±assy
Exhaust manifold x Cylinder head sub±assy
9.5
5.0
5.0
9.5
9.597
51
51
97
9784 in.
lbf
44 in.
lbf
44 in.
lbf
84 in.
lbf
84 in.
lbf
W/ Head taper screw plug No. 2 x Cylinder head sub±assy4444933
Crankshaft bearing cap sub±assy x Cylinder block sub±assy M10 1st
2nd3rd
M822
44
Turn 90
19224
449
Turn 90
19416
33
Turn 90
14
Connecting rod x Connecting rod cap 1st
2nd20
Turn 90
204
Turn 90
15
Turn 90

Stud bolt
Water by±pass pipe No. 1 x Cylinder block sub±assy
Water inlet x Cylinder block sub±assy
Oil strainer sub±assy x Cylinder block sub±assy
Oil pan sub±assy x Cylinder block sub±assy
Knock control sensor x Cylinder block sub±assy
5.0
5.0
5.0
5.0 1151
51
51
51
11 244 in.
lbf
44 in.
lbf
44 in.
lbf
44 in.
lbf
8
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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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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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