TOYOTA AVENSIS 2003 Service Repair Manual

A62224
A37017
A37020
A62225
Free
Lock
A33580
±
STARTING & CHARGING STARTER ASSY (1ZZ±FE/3ZZ±FE)
19±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
8. INSPECT BRUSH
(a) Using a vernier calipers, measure the brush length. Standard length: 14 mm (0.551 in.)
Minimum length: 9 mm (0.354 in.)
9. INSPECT STARTER BRUSH HOLDER ASSY
(a) Using an ohmmeter, check that there is no continuity be- tween the positive (+) and negative (±) brush holders.
10. INSPECT STARTER CLUTCH SUB±ASSY
(a) Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
11. INSPECT MAGNET STARTER SWITCH ASSY
(a) Push in the plunger and check that it returns quickly to its original position.
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A62226Terminal 50Terminal C
A62227Terminal 50
Switch Body
A33607
A33608
A33587
19±6
±
STARTING & CHARGING STARTER ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Using an ohmmeter, check that there is continuity be- tween terminals 50 and C.
(c) Using an ohmmeter, check that there is continuity be- tween terminals 50 and the switch body.
12. INSTALL STARTER CLUTCH SUB±ASSY
(a) Apply grease to the bushing and spline of the starter clutch and stop collar.
(b) Place the starter clutch and stop collar on the planetary
shaft.
(c) Apply grease to the snap ring, and install it to the plane- tary shaft groove.
(d) Using a vise, compress the snap ring.
(e) Hold the starter clutch, tap the planetary shaft and install the stop collar onto the snap ring with a plastic hammer.
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ST0741
Grease
A62228
CutoutProtrusion
A30137
ST0728
±
STARTING & CHARGING STARTER ASSY (1ZZ±FE/3ZZ±FE)
19±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(f) Apply grease to the drive lever touching the starter pivot
part of the drive lever.
(g) Install the drive lever to the starter clutch.
(h) Align the protrusion of the shock absorber with the cutout of the starter housing and install them.
13. INSTALL STARTER ARMATURE ASSY
(a) Install the starter armature to the starter yoke. 14. INSTALL STARTER BRUSH HOLDER ASSY
(a) Install the brush holder.
(b) Using a screwdriver, hold the brush spring back, and con-nect the brush into the brush holder.
Connect the 4 brushes.
(c) Apply turbine oil with additives to the bearing of the end frame.
(d) Install the end frame with 2 new screws. Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf)
NOTICE:
To avoid interference between the brush holder and the
dust protector push the commutator and frame away at an
angle.
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A62229
ProtrusionCutout
A34019
ST0742
A37086
19±8
±
STARTING & CHARGING STARTER ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSTALL STARTER YOKE ASSY
(a) Align the cutout of the field frame with the protrusion of the shock absorber.
(b) Install the field frame and armature assembly with the 2 through bolts.
Torque: 5.9 N
m (60 kgf
cm, 52 in.
lbf)
16. INSTALL MAGNET STARTER SWITCH ASSY
(a) Hang the plunger of the magnetic switch to the driver lever from the upper side.
(b) Install the magnetic switch with the 2 nuts. Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
(c) Connect the lead wire to the terminal with the nut. Torque: 9.8 N
m (100 kgf
cm, 7 ft
lbf)
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1600R±13
±
COOLING COOLING FAN SYSTEM (1AZ±FE)
16±17
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switc\
h is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 77
C (171
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolan\
t temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 95.5
C (204
F))
(a) Start the engine, and raise coolant temperature to above 95.5
C (204
F).
HINT:
Coolant temperature is the detected value by the engine coolant temperat\
ure sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
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160N3±01
E34090
A30519
E34090
16±18
±
COOLING COOLING FAN SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COOLING FAN RELAY
(a) Continuity inspection. (1) Using an ohmmeter, check for continuity betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
2. INSPECT COOLING FAN RELAY NO.2
(a) Continuity inspection. (1) Using an ohmmeter, check for continuity betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2
3 ± 4Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
3. INSPECT COOLING FAN RELAY NO.3
(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)
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1600R±12
±
COOLING COOLING FAN SYSTEM (1AZ±FSE)
16±29
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FSE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switc\
h is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolan\
t temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 100
C (212
F))
(a) Start the engine, and raise coolant temperature to above 100
C (212
F).
HINT:
Coolant temperature is the detected value by the engine coolant temperat\
ure sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
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160N0±01
E34090
A30519
E34090
16±30
±
COOLING COOLING FAN SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COOLING FAN RELAY
(a) Continuity inspection. (1) Using an ohmmeter, check for continuity betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery boltage terminals 1 and 2)
2. INSPECT COOLING FAN RELAY NO.2
(a) Continuity inspection. (1) Using an ohmmeter, check for continuity betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2
3 ± 4Continuity
No continuity
3 ± 5Continuity
(Apply battery boltage terminals 1 and 2)
3. INSPECT COOLING FAN RELAY NO.3
(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 boltage terminals 1 and 2)
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1606N±03
A57065
21


±
COOLING COOLING FAN SYSTEM (1CD±FTV)
16±41
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
(c) Disconnect the temperature detect switch connector.
(d) Connect the terminals on the temperature detect switch connector.
(e) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay and cooling fan, and check for \
a open circuit between the cooling
fan relay and temperature detect switch.
(f) Reconnect the temperature detect switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 93
C (199
F))
(a) Start the engine, and raise coolant temperature to above 93
C (199
F)
HINT:
Coolant temperature is the detected value by the temperature detect swit\
ch on the radiator lower tank.
(b) Check that the cooling fan rotates.
If not, replace the temperature detect switch.
3. INSPECT COOLING FANS
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connec-tor.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
Approx. 13.2 A at 20
C (68
F)
(d) Reconnect the cooling fan connector.
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160N8±01

 




A35654
A30519
E34090
16±42
±
COOLING COOLING FAN SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COOLING FAN RELAY
(a) Continuity inspection. (1) Using an ohmmeter, check for continuity betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
2. INSPECT COOLING FAN RELAY NO.2
(a) Continuity inspection. (1) Using an ohmmeter, check for continuity betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2
3 ± 4Continuity
No continuity
3 ± 5Continuity
(Apply battery boltage terminals 1 and 2)
3. INSPECT COOLING FAN RELAY NO.3
(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)
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