charging TOYOTA AVENSIS 2003 Service User Guide

110UT±01
A75341
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
±
FUELFUEL SYSTEM(1ZZ±FE/3ZZ±FE)
11±1
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts.
2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec-
tion to catch any fuel that may spill.
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110V0±01
Fuel Tube Connector
A50710
A60083
Fuel Pipe
Clamp No.1
AA
B12941
±
FUELFUEL SYSTEM(1AZ±FSE)
11±33
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1.CHECK FUEL PRESSURE
(a)Discharge the pressure in the fuel system and take pre-
cautions for possible fuel spillage. (See page 11±30)
(b) Check that the battery voltage is above 12 V.
(c) Disconnect the negative (±) battery cable.
(d) Pull out the connecter from a new fuel tube.
HINT:
Part No. 23901±28160
(e) Disconnect the fuel tube clamp from the fuel tube connec- tor.
(f) Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustra-
tion.
CAUTION:

Do not disconnect the fuel tube connector (quick
type) until after you have discharged the fuel system
pressure and taken appropriate steps to prevent fuel
spillage.

There may be remained pressure in the fuel lines after
discharging the pressure.
Take precautions to prevent fuel from spraying on
you or your clothing or inside the engine compart-
ment.
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110UZ±01
A75339
Fuel
Pump
Connector
B00679
Vinyl or Plastic Bag
11±30
±
FUELFUEL SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
FUEL SYSTEM(1AZ±FSE)
PRECAUTION
1.PRECAUTION
(a)Before working on fuel system, disconnect negative (±) battery cable.
(b)Do not smoke or work near fire when handling the fuel system.
(c)Keep gasoline away from rubber or leather parts. 2.DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:

Do not disconnect any part of the fuel system until
you have discharged the fuel system pressure.

Even after discharging the fuel pressure, place a
shop rag over fittings as you separate them to reduce
risk of fuel spray on yourself or in the engine compart-
ment.
(a)Disconnect the fuel pump connector.
(b)Start the engine. After the engine has stopped, turn the ignition switch OFF.
(c)Disconnect the negative (±) battery cable.
(d)Connect the fuel pump connector.
3.FUEL SYSTEM
(a)When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these proce-
dures.
(1)Discharge the pressure in the fuel system. (See step 2)
(2) Disconnect the fuel pump tube. (See page 11±93)
(3) Drain the fuel that remained inside the fuel pump
tube.
(4) Cover the disconnected fuel pump tubes with a vinyl or a plastic bag to prevent damage and dirt.
(5) Place a tray under the vehicle or point of disconnec- tion to catch any fuel that may spill.
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1302Z±03
A77123
SST
A60595E2 VC
±
INTAKE TURBO CHARGER SYSTEM (1CD±FTV)
13±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT INTAKE AIR SYSTEM
(a) Check for leakage or clogging between the air cleaner
housing and turbocharger inlet and between the turbo-
charger outlet and cylinder head.
(1) Clogged air cleaner...Clean or replace element
(2) Hoses collapsed or deformed...Repair or replace
(3) Leakage from connections...Check each connec-tion and repair
(4) Cracks in components...Check and replace
2. INSPECT EXHAUST SYSTEM
(a) Check for leakage or clogging between the cylinder head
and turbocharger inlet and between the turbocharger out-
let and exhaust pipe.
(1) Deformed components...Repair or replace
(2) Foreign material in passages...Remove
(3) Leakage from components...Repair or replace
(4) Cracks in components...Check and replace
3. CHECK TURBOCHARGING PRESSURE
(a) Warm up the engine.
(b) Using a 3±way connector, connect SST (turbocharger pressure gauge) to the hose leading to the intake air con-
nector.
SST 09992 ± 00242
(c) While depressing the clutch pedal, press the accelerator pedal down to the full. Measure the turbocharging pres-
sure at maximum speed (5,100 to 5,250 rpm).
Standard pressure:
15 to 45 kPa (0.15 to 0.46 kgf/cm
2, 2.2 to 6.5 psi)
If the pressure is less than specification, check both the intake
air and exhaust systems for leakage.
If there is no leakage, check if the actuator hose has discon-
nected. If not, check the turbocharger.
If the pressure is greater than specification, check if the actua-
tor hose has disconnected or cracked. If not, check the turbo-
charger.
4. INSPECT TURBO PRESSURE SENSOR
(a) Inspect power source voltage (1) Disconnect the turbo pressure sensor connector.
(2) Turn the ignition switch ON.
(3) Using a voltmeter, measure the voltage between
connector terminals 3 (VC) and 1 (E2) of the wiring
harness side.
Voltage: 4.5 to 5.5 V
(4) Turn the ignition switch OFF.
(5) Reconnect the turbo pressure sensor connector.
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A64005
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±31
AVENSIS REPAIR MANUAL (RM1018E)
40.REMOVE GENERATOR ASSY (See page 19±7)
41. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

Secure the compressor and hoses off to the side instead of discharging the A/C system.

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
42. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and the column hole cover silencer sheet.
43.SEPARATE STEERING INTERMEDIATE SHAFT (See page 50±9)
44.REMOVE FRONT DOOR SCUFF PLATE RH (See page 71±11)
45.REMOVE COWL SIDE TRIM BOARD RH (See page 71±11)
46. REMOVE FRONT FLOOR FOOTREST
47. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and the floor panel brace front.
48.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±2)
49.REMOVE FRONT AXLE HUB LH NUT (See page 30±6)
SST 09930±00010
50. REMOVE FRONT AXLE HUB RH NUT SST 09930±00010
HINT:
Perform the same procedure as above on the opposite side.
51.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6)
SST 09628±62011
52. SEPARATE TIE ROD END SUB±ASSY RH SST 09628±62011
HINT:
Perform the same procedure as above on the opposite side.
53.SEPARATE FRONT STABILIZER LINK ASSY LH (See page 30±6)
54. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
55.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
56. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
57.SEPARATE FRONT AXLE ASSY LH (See page 30±6)
58. SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.
(b) Remove the 4 bolts and 2 nuts, and detach the enginemounting insulator.
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02148±01
±
PREPARATION STARTING & CHARGING
02±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
STARTING & CHARGING
PREPARATION
SST
09286±46011Injection Pump Spline Shaft
PullerGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
09820±63010Alternator Pulley Set Nut Wrench
SetGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09820±06010)Alternator Rotor Shaft WrenchGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09820±06020)Alternator Pulley Set Nut 22 mm
WrenchGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
Recomended Tools
09011±12291Socket Wrench for 29 mm .GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
09082±00040TOYOTA Electrical TesterSTARTER ASSY
(1ZZ±FE/3ZZ±FE)
GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetSTARTER ASSY
(1ZZ±FE/3ZZ±FE)
GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
Equipment
Ohmmeter
Sandpaper
V±block
Dial indicator
Vernier calipers
Plastic hammer
Torque wrench
Wooden block
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0300Q±02
03±10
±
SERVICE SPECIFICATIONS STARTING & CHARGING
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
STARTING & CHARGING
SERVICE DATA
Starter armature assy
Circle runout Maximum
Commutator diameter Standard Minimum
Undercut depth Standard Minimum
0.05 mm (0.0020 in.)
28 mm (1.102 in.)
27 mm (1.063 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
Starter yoke assy
Brush length StandardMinimum
14 mm (0.551 in.)
9 mm (0.354 in.)
Starter brush holder assy
Brush length StandardMinimum
14 mm (0.551 in.)
9 mm (0.354 in.)
Generator rotor assy
Coil resistance at 20
C (68
F)
Slip ring diameter Standard
Minimum
2.1 ± 2.5

14.2 ± 14.4 mm (0.559 ± 0.567 in.)
12.8 mm (0.504 in.)
Generator brush holder assy
Exposed brush length StandardMinimum
9.5 ± 11.5 mm (0.374 ± 0.453 in.)
1.5 mm (0.059 in.)
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0300R±02
±
SERVICE SPECIFICATIONS STARTING & CHARGING
03±11
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Starter commutator end frame assy x Starter brush holder assy1.51513 in.
lbf
Starter yoke assy x Starter drive housing assy5.96052 in.
lbf
Magnet starter switch assy x Starter drive housing assy8.38573 in.
lbf
Lead wire x Magnet starter switch assy9.81007
Generator rectifier end frame x Generator drive end frame w/o cord clip
w/ cord clip4.5
5.446
5540 in.
lbf
48 in.
lbf
Generator holder w/ rectifier x Generator drive end frame2.93026 in.
lbf
Generator regulator x Generator holder w/ rectifier2.02018 in.
lbf
Generator brush holder assy x Generator holder w/ rectifier2.02018 in.
lbf
Generator rear end cover x Generator rectifier end frame4.44539 in.
lbf
Terminal plate x Generator rectifier end frame Bolt
Nut3.9
4.440
4535 in.
lbf
39 in.
lbf
Terminal insulator x Generator holder w/ rectifier4.14236 in.
lbf
Generator pulley x Generator rotor assy1111,13282
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190A9±01
A62217
Generator PulleyGenerator Drive End Frame
Terminal Insulator
Generator Rotor Assy Washer
Generator Rectifier End Frame Generator
Cord Clip
Generator Plate SealGenerator Holder W/ Rectifier
Generator Regulator
Generator Brush Holder Assy Generator Brush Cover
Terminal Plate
Terminal Insulator
111 (1,132, 82)
2.9 (30, 26 in.
lbf)
4.4 (45, 39 in.
lbf)
3.9 (40, 35 in.
lbf)
2.0 (20, 18 in.
lbf)
2.0 (20, 18 in.
lbf)
4.5 (46, 40 in.
lbf) W/O Cord Clip
5.4 (55, 48in.
lbf) W/ Cord Clip
4.1 (42, 36 in.
lbf)
Generator Rear End Cover
N´m (kgf´cm, ft´lbf)
: Specified torque
±
STARTING & CHARGING GENERATOR ASSY (1ZZ±FE/3ZZ±FE)
19±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
GENERATOR ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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190AA±01
A62753
SST
1 ± BSST
1 ± A
A62754SST 2
A62755
SST
1 ± A
A62756
SST
1 ± A
SST
1 ± B
19±10
±
STARTING & CHARGING GENERATOR ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE GENERATOR PULLEY SST 09820±63010 (09820±06010, 09820±06020)
HINT:
SST1 ± A, B09820±06010
SST209820±06020
(a) Hold SST 1 ± A with a torque wrench, and tighten SST 1 ± B clockwise to the specified torque.
Torque: 39 N
m (398 kgf
cm, 29 ft
lbf)
NOTICE:
Check that SST is secured to the rotor shaft.
(b) Mount SST 2 in a vise.
(c) Insert SST 1 ± A, B into SST 2, and attach the pulley nut to SST 2.
(d) To loosen the pulley nut, turn SST 1 ± A in the direction shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one±half of a turn.
(e) Remove the alternator form SST 2.
(f) Turn SST 1 ± B, and remove SST 1 ± A, B.
(g) Remove the pulley nut and pulley.
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