TOYOTA AVENSIS 2002 Repair Manual

190O0±01
19±24
±
STARTING & CHARGING STARTER ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
STARTER ASSY(1CD±FTV)
REPLACEMENT
1.DRAIN ENGINE COOLANT(See page 16±44)
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE RADIATOR RESERVE TANK ASSY(See page 16±50)
4.REMOVE AIR CLEANER ASSY (See page 14±286)
5.REMOVE BATTERY
6.REMOVE STARTER ASSY
(a)Remove the nut and disconnect terminal 30.
(b)Disconnect the starter connector.
(c)Remove the 2 bolts and the starter.
7.INSTALL STARTER ASSY Torque:
37 N
m (377 kgf
cm, 27 ft
lbf) for bolt
9.8 N
m (100 kgf
cm, 7.2 ft
lbf) for terminal 30
8.INSTALL AIR CLEANER ASSY (See page 14±286)
9.INSTALL RADIATOR RESERVE TANK ASSY(See page 16±50)
10.ADD ENGINE COOLANT(See page 16±44)
11.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)

190NH±01
A78485
(a)
Terminal
Cap Cover
(b)
A78486
±
STARTING & CHARGING STARTER ASSY(1ZZ±FE/3ZZ±FE)
19±3
AVENSIS REPAIR MANUAL (RM1018E)
STARTER ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 10±17)
2. REMOVE STARTER ASSY
(a) Disconnect the starter connector.
(b) Open the terminal cap cover.
(c) Remove the nut and disconnect the starter wire.
(d) Remove the 2 bolts, and then remove the starter.
3. INSTALL STARTER ASSY Torque:
37 N
m (378 kgf
cm, 28 ft
lbf) for bolt
9.8 N
m (100 kgf
cm, 7 ft
lbf) for nut
4. INSTALL ENGINE UNDER COVER SUB±ASSY NO.1

190NU±01
A78629
Terminal CTerminal 50
A78630Disconnect
A78631
Disconnect
19±8
± STARTING & CHARGINGSTARTING SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
STARTING SYSTEM (1AZ±FE)
INSPECTION
1. INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
(a) Do pull±in test
(1) Disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnetic switch as
shown in the illustration on the left. Check that the
clutch pinion gear is extended.
If the clutch pinion gear is not extended, replace the magnetic
switch.
(b) Do hold±in test
(1) Disconnect the negative (±) lead from terminal C
with the above condition (a) is being maintained.
Check that the pinion gear remains extended.
If the clutch pinion gear returns, replace the magnetic switch.
(c) Inspect clutch pinion gear return
(1) Disconnect the negative (±) lead from the switch
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.

A78632
Terminal 30
Terminal 50
Ammeter
B16200
± STARTING & CHARGINGSTARTING SYSTEM (1AZ±FE)
19±9
AVENSIS REPAIR MANUAL (RM1018E)
(d) Do no±load performance test
(1) Connect the field coil lead wire to terminal C. Make
sure that the lead is not grounded.
Torque: 5.9 N
m (60 kgf
cm, 52 in
lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current: 85 A or less at 11.5 V
2. INSPECT STARTER RELAY ASSY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)

190NR±01
A78629
Terminal CTerminal 50
A78630Disconnect
A78631
Disconnect
19±10
± STARTING & CHARGINGSTARTING SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
STARTING SYSTEM (1AZ±FSE)
INSPECTION
1. INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
(a) Do pull±in test
(1) Disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnetic switch as
shown in the illustration on the left. Check that the
clutch pinion gear is extended.
If the clutch pinion gear is not extended, replace the magnetic
switch.
(b) Do hold±in test
(1) Disconnect the negative (±) lead from terminal C
with the above condition (a) is being maintained.
Check that the pinion gear remains extended.
If the clutch pinion gear returns, replace the magnetic switch.
(c) Inspect clutch pinion gear return
(1) Disconnect the negative (±) lead from the switch
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.

A78632
Terminal 30
Terminal 50
Ammeter
B16200
± STARTING & CHARGINGSTARTING SYSTEM (1AZ±FSE)
19±11
AVENSIS REPAIR MANUAL (RM1018E)
(d) Do no±load performance test
(1) Connect the field coil lead wire to terminal C. Make
sure that the lead is not grounded.
Torque: 5.9 N
m (60 kgf
cm, 52 in
lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current:
1.3kw 85 A or less at 11.5 V
1.6kw 75 A or less at 11.5 V
2. INSPECT STARTER RELAY ASSY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Applying battery voltage terminals 1 and 2)

190NL±01
A78633
Terminal CTerminal 50
A78634Disconnect
A78635
Disconnect
19±22
± STARTING & CHARGINGSTARTING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
STARTING SYSTEM (1CD±FTV)
INSPECTION
1. INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
(a) Do pull±in test
(1) Disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnetic switch as
shown in the illustration on the left. Check that the
clutch pinion gear is extended.
If the clutch pinion gear is not extended, replace the magnetic
switch.
(b) Do hold±in test
(1) Disconnect the negative (±) lead from the terminal
C with the above condition (a) is being maintained.
Check that the pinion gear remains extended.
If the clutch pinion gear returns, replace the magnetic switch.
(c) Inspect clutch pinion gear return
(1) Disconnect the negative (±) lead from the switch
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.

A78637
Terminal 30
Terminal 50
Ammeter
B16200
± STARTING & CHARGINGSTARTING SYSTEM (1CD±FTV)
19±23
AVENSIS REPAIR MANUAL (RM1018E)
(d) Do no±load performance test
(1) Connect the field coil lead wire to terminal C. Make
sure that the lead is not grounded.
Torque: 5.9 N
m (60 kgf
cm, 52 in
lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current: 190 A or less at 11.5 V
2. INSPECT STARTER RELAY ASSY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)

190NO±01
A82615Terminal CTerminal 50
A82616Terminal C Terminal 50
A82617
Terminal C Terminal 50
± STARTING & CHARGINGSTARTING SYSTEM (1ZZ±FE/3ZZ±FE)
19±1
AVENSIS REPAIR MANUAL (RM1018E)
STARTING SYSTEM (1ZZ±FE/3ZZ±FE)
INSPECTION
1. INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
(a) Do pull±in test
(1) Disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnetic switch as
shown in the illustration on the left. Check that the
clutch pinion gear is extended.
If the clutch pinion gear is not extended, replace the magnetic
switch.
(b) Do hold±in test
(1) Disconnect the negative (±) lead from terminal C
with the above condition (a) is being maintained.
Check that the pinion gear remains extended.
If the clutch pinion gear returns, replace the magnetic switch.
(c) Inspect clutch pinion gear return
(1) Disconnect the negative (±) lead from the switch
body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.

A82618Terminal C Terminal 50
B16200
19±2
± STARTING & CHARGINGSTARTING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Do no±load performance test
(1) Connect the field coil lead wire to terminal C. Make
sure that the lead is not grounded.
Torque: 5.9 N
m (60 kgf
cm, 52 in
lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter
as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily
with the clutch pinion gear extended. Check that the
ammeter reads the specified current.
Specified current: 85 A or less at 11.5 V
2. INSPECT STARTER RELAY ASSY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuIty
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)