Avanza-Radiator fan motor modification

The continuous increase of surface temperature due to El Nino phenomena
calls for a more powerful cooling/radiator fan motor
to be modified onto the existing  assembly of my Toyota Avanza
instead of adding another fan infront of the air-con condensor
which will drain more power from the battery
and could in some case restrict the air flow passing through
the radiator when the car is at high speed.
A well thought out idea and a great job
by 'Ah Boy' of KC ZONE Air Con
at Taman Ketari,Bentong,Pahang.
(017-6721332)









enlarging the assembly to fit the bigger motor with a grinder.











a bigger capacity relay is used

Toyota Avanza mini OCT mode

This engine PCV(positive crankcase ventilation)system
is designed to regulate and remove fumes from the engine crankcase
and to alleviate crankcase pressure which could cause oil leaks or seal damage.
 It’s a way for gases to escape in a controlled manner
from the crankcase of an internal combustion engine.
Part of the fume includes oil mist which will dirty the intakes
and cause carbon buildup in the cylinder head
and here comes the mini Oil Catch Tank to trap off the oil mist.

 



Install the filter with the direction indicator pointing this way.




Oil mist will be trapped and retained at the bottom of  the filter
and it's best to replace it once a year.



Please stick  a Superlon sponge padding between the filter and the manifold
to avoid wear on the manifold.



notice the oil at the bottom after 3 months,

Avanza-Things to know about the rear suspension

A layman's view about the rear suspension of an earlier model Toyota Avanza (2004-2011)
which have given owners many sleepless nights pondering on how to  overcome it's bounciness
but it's good to know that latest model have much improve ones.
Our earlier cheap antidote was by using the set of yellow of KYB Ultra front and rear abs
ordered from Indonesia and used with original springs
but time had taken a toll on it and it's now due for a change,
that's where the locally made KYB RS Ultra comes in.
 The best solution so far that is if you can afford it
is a set of custom made Titan Suspension
with a slightly lowered pair of used BMW's
320i E36 springs at the rear.









The rear absorber travel distance, normal height and bump stop gap,
used too low a spring means the absorber touching bottom
and damaging it's valve.Cutting or using a shorter bump stopper
should be limited to 57 mm height(from 77 mm)
and a minimum spring height at 220 mm
that is assuming you are using a KYB RS Ultra.



Our earlier solution,KYB Ultra SP8439.
Layman's way of checking the absorber,
the KYB SP8439 and the newer made in Malaysia KYB RS Ultra
seems to be the best cheap solution so far used together
with it's front ones.





KYB RS Ultra front and rear is now the best cheap replacement
at a price between RM420 ~460 depending on where you buy it.



The length and wire diameter of the original rear spring for reference,
just in case you need to look for a lower second hand one.





The maximum and minimum length or the KYB RS Ultra absorber.



The gap between the rubber bump stopper and the rear axle when unloaded.



3 inches is the length of the original bump stopper.




This is an example with a sports spring which is too soft
and a bump stopper gap of around 1.5 inches without load.



and almost touching when loaded,
so much for the so called sports spring.



The length of the ori rear spring is 260 mm or 10.25 inches.








A replacement spring will need an opening of about 53 mm at both ends to fit nicely onto the rubber seat
and a height of not less than 220 mm or else you will risk having your rear spring dropping off when you speed through humps and the annoying feeling of the rear bump stopper touching the rear axle
every time  you carry extra load on your Avanza.



The bottom and top rubber seat diameter at 54 mm.







The set of Titan front adjustable and rear absorber
with a lower E36 spring at the rear,
both these absorber are adjustable
and can be tuned to suit your driving preference
at a price starting from around RM2,400
but if one can't afford the luxury like me
then just stick  to the proven KYB RS Ultra




The E36 spring compared with ori.




Titan front compared with ori.

Avanza~Radiator Fan motor replacement

This is a DIY preventive maintenance for the replacement
of Toyota Avanza's radiator fan motor.
The electric radiator fan serves to cool the engine(coolant)
and the car air condition's condensor
and it's supposed to be maintenance free
that is if you were to use your vehicle for only 5 years
or around 180,000km,
anything more than that will require a replacement
or at least a service with carbon brush and bearing replacement.
(Beside the radiator fan motor,starter motor
and alternator will also require similar maintenance when the time comes)

 

The new radiator fan motor.



The mileage of my Avanza at 180,000km(from Dec 2004) during the motor replacement.



Some  tools for the job,
a short +screw driver,a normal - screw driver,a 10/12mm socket spanner
and an 8mm combination spanner.



A photo of the radiator fan motor.



As a safety precaution pls remove the car key from the ignition switch
before the work starts.
This replacement work can be done by your car mechanic
or by DIY for those who likes to get their hand dirty.
here are the directions,it will be done it without taking the radiator fan out from the engine compartment,
1) Use the screw driver to press on the knob below to release the lock
and slowly pull out the power supply socket.



there are 2 bolts at the top holding the radiator fan casing to the radiator
and 2 pins securing  the bottom part.







2) Remove the 2 bolts with the 10mm socket spanner.



3) After the bolts have been removed,
pull up the radiator motor housing a little
so that the 2 pins are out from its hole like below
to allow for more space for the motor replacement work.



4) Use the 8mm combination spanner to remove the radiator fan nut
(hold the fan when loosening the nut)
and pull it out from the motor shaft
(notice the  key way on the fan)





The 8mm nut circled red.
5) After the fan have been removed,
loosen and remove the 3 screw securing the motor to the housing
with the short + screw driver,
remove the old motor and replace with new.
6) Reinstall back the 3 screws tightly
followed by the inserting the fan to the motor shaft(making sure the key way is correctly positioned) and reinstall  the 8mm nut to secure the fan to the motor.

7)Pull up the radiator fan bracket a little
and reinsert the 2 bottom pins into the hole on the radiator
and retighten the 2 X 10mm bolt.

8) Reinsert the power supply socket onto the motor.
(visual check to see whether the everything is in order,
remove tools and start the engine
to test the fan which only runs when the engine temperature is above 98 deg c)


The old motor.








At 180,000km the carbon brush is almost finishing,
i would say it can go for another risky 20k before breaking down.