TOYOTA AVENSIS 2003 Service Repair Manual

A77905
A77906
A77905
A
B
±
STARTING & CHARGING GENERATOR ASSY (1AZ±FE/1AZ±FSE)
19±21
AVENSIS REPAIR MANUAL (RM1018E)
(g) Remove the 2 bolts, and then remove the generator.
(h) Remove the bolt, and then remove the wire harness
clamp bracket.
7. INSTALL GENERATOR ASSY
(a) Install the wire harness clamp bracket wire the bolt. Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
(b) Install the generator the 2 bolts. Torque:
52 N
m (530 kgf
cm, 38 ft
lbf) for bolt A
21 N
m (214 kgf
cm, 16 ft
lbf) for bolt B
(c) Install the 2 wire harness clamps.
(d) Connect the generator connector.
(e) Install the generator wire with the nut. Torque: 9.8 N
m (100 kgf
cm, 7 ft
lbf)
(f) Install the terminal cap.
(g) Install the 2 connector clamps of the heated oxygen sen- sor and the wire harness clamp.
(1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(h) Connect the 2 heated oxygen sensor connectors. (1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
8. INSTALL FAN AND GENERATOR V BELT
SST 09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
9. INSTALL ENGINE ROOM COVER SIDE
10. INSTALL RADIATOR SUPPORT OPENING COVER
11. INSTALL ENGINE UNDER COVER RH
12. INSTALL ENGINE UNDER COVER LH
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190O1±01
A79176
±
STARTING & CHARGINGGENERATOR ASSY(1CD±FTV)
19±29
AVENSIS REPAIR MANUAL (RM1018E)
GENERATOR ASSY(1CD±FTV)
REPLACEMENT
1.REMOVE FRONT WHEEL RH
2.REMOVE RADIATOR SUPPORT OPENING COVER
3.REMOVE ENGINE ROOM COVER SIDE
4.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
7.REMOVE GENERATOR V BELT (See page 14±269)
8.REMOVE FLOOR PANEL BRACE FRONT(See page 15±10)
9.REMOVE EXHAUST PIPE ASSY FRONT(See page 15±10)
10.REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
11.REMOVE GENERATOR ASSY
(a)Remove the bolt and disconnect the wire harness.
(b)Remove the cap and nut, disconnect the generator wire.
(c)Disconnect the generator connector.
(d)Remove the 2 bolts and the generator.
12.INSTALL GENERATOR ASSY Torque:
31 N
m (320 kgf
cm, 23 ft
lbf) for M8
47 N
m (475 kgf
cm, 34 ft
lbf) for M10
9.8 N
m (100 kgf
cm, 7 ft
lbf) for Generator wire
5.0 N
m (51 kgf
cm, 44 ft
lbf) for Wire harness
13.INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 13±11)
14.INSTALL EXHAUST PIPE ASSY FRONT(See page 15±10)
15.INSTALL FLOOR PANEL BRACE FRONT(See page 15±10)
16. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±286)
17. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18. CHECK FOR EXHAUST GAS LEAKS
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190NI±01
A78487
(a)
(d)
(e)
(c)
Terminal Cap No. 2
A78488
A78488
A
B
±
STARTING & CHARGINGGENERATOR ASSY(1ZZ±FE/3ZZ±FE)
19±7
AVENSIS REPAIR MANUAL (RM1018E)
GENERATOR ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 10±17)
2.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±9)
3.REMOVE ENGINE ROOM COVER SIDE (See page 10±9)
4.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
5.REMOVE GENERATOR ASSY
(a)Disconnect the generator connector.
(b)Remove the terminal cap No. 2.
(c)Remove the nut and disconnect the generator wire.
(d)Disconnect the A/C connector. (w/ Air Conditioning)
(e)Remove the wire harness clamp. (w/ Air Conditioning)
(f)Remove the 2 bolts, and then remove the generator.
6.INSTALL GENERATOR ASSY
(a)Install the generator with the 2 bolts. Torque:
25 N
m (255 kgf
cm, 18 ft
lbf) for bolt A
54 N
m (551 kgf
cm, 40 ft
lbf) for bolt B
(b)Install the wire harness clamp. (w/ Air Conditioning)
(c)Connect the A/C connector. (w/ Air Conditioning)
(d)Install the generator wire with the nut. Torque: 9.8 N
m (100 kgf
cm, 7 ft
lbf)
(e)Install the terminal cap No. 2.
(f)Connect the generator connector.
7.INSTALL FAN AND GENERATOR V BELT (See page 14±5)
8. INSTALL ENGINE ROOM COVER SIDE
9. INSTALL RADIATOR SUPPORT OPENING COVER
10. INSTALL ENGINE UNDER COVER SUB±ASSY NO.1
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190O2±01
A79177
±
STARTING & CHARGING GLOW PLUG ASSY (1CD±FTV)
19±33
AVENSIS REPAIR MANUAL (RM1018E)
GLOW PLUG ASSY (1CD±FTV)
REPLACEMENT
1. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
2. REMOVE GLOW PLUG ASSY
(a) Remove the 5 grommets.
(b) Remove the 5 nuts and the glow plug connector.
(c) Remove the 4 glow plugs.
3. INSTALL GLOW PLUG ASSY Torque:
12.3 N
m (125 kgf
cm, 9 ft
lbf) for glow plug
2.2 N
m (22 kgf
cm, 19 in.
lbf) for nut
4. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
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190JE±02
A82619
Light Lightning Time
Water Temperature
±20 0 28
0
±4 32 (
F)
(

C)
82.4
(sec.)
10
3
1
A72562
Pre±heating Time (sec)Battery Voltage [V]
A80155
After Glow Time
Water Temperature 68 104 (

F)
020 40(

C)
(sec.)
1
19±30
±
STARTING & CHARGING PRE±HEATING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
PRE±HEATING SYSTEM (1CD±FTV)
ON±VEHICLE INSPECTION
NOTICE:
Turn the ignition switch OFF for 60 seconds before performing the followi\
ng inspections. 1. INSPECT LIGHTING DURATION OF GLOW INDICA-TOR LIGHT
(a) Turn the ignition switch ON, and measure the lighting duration.
Light lighting duration: Refer to the chart graph
2. INSPECT PRE±HEATING
(a) Turn the ignition switch ON, measure how long it takes to the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
(b) Turn the ignition switch STA, check that the battery volt- age applied to the glow plugs.
SST 09082±00030, 09083±00150
(c) While cranking the engine, measure how long it takes to
the battery voltage is applied to the glow plugs.
SST 09082±00030, 09083±00150
Pre±Heating time:
Engine coolant temperaturePre±Heating time
40
C or more1 sec
40
C or lessRefer to the chart graph
(15 sec at the longest)
3. INSPECT AFTER GLOW TIME
(a) After the engine starting, measure how long it takes to the battery voltage is applied to the terminal SREL of the
ECM.
After glow time: Refer to the chart graph
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B08263
OhmmeterContinuity
±
STARTING & CHARGING PRE±HEATING SYSTEM (1CD±FTV)
19±31
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT GLOW PLUGS
(a) Using an ohmmeter, check that there is continuity be-
tween the glow plug terminal and ground.
Standard resistance: Approx. 0.72
at 20 C (68 F)
NOTICE:

Be careful not to damage the glow plug pipes as it
could cause an open circuit or shorten life of the glow
plugs.

Avoid getting oil and gasoline on the glow plug when
cleaning.

Wipe up any oil on the terminal and Bakelite washer
with a dry cloth if they are stained with oil during in-
spection.

Be careful not to apply more than 11 V to the glow plug
as it could cause an open circuit.
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190JF±02


A34838
19±32
±
STARTING & CHARGING PRE±HEATING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT GLOW PLUG RELAY ASSY
(a) Using an ohmmeter, check for continuity between each terminal.
Specified condition:
No continuity
1 ± 2Continuity
(Apply battery voltage terminals 3 and 4)
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190NJ±01
A77898
A77899
(a)
(a)
(a)(c)
(d)
Terminal Cap Cover
A77900
A77901
19±12
±
STARTING & CHARGINGSTARTER ASSY(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
STARTER ASSY(1AZ±FE/1AZ±FSE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
2. REMOVE BATTERY CLAMP SUB±ASSY
3. REMOVE BATTERY
4. REMOVE BATTERY TRAY 5. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts, and then remove the battery carrier.
6. REMOVE STARTER ASSY
(a) Remove the 3 wire harness clamps.
(b) Open the terminal cap cover.
(c) Remove the nut and disconnect the starter wire.
(d) Disconnect the starter connector.
(e) Remove the 2 bolts, and then remove the starter.
(f) Remove the bolt, and then remove the wire harnessclamp bracket.
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±
STARTING & CHARGING STARTER ASSY (1AZ±FE/1AZ±FSE)
19±13
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL STARTER ASSY
(a) Install the wire harness clamp bracket with the bolt.
Torque: 8.4 N
m (86 kgf
cm, 74 in.
lbf)
(b) Install the starter with the 2 bolts. Torque: 37 N
m (380 kgf
cm, 28 ft
lbf)
(c) Connect the starter connector.
(d) Connect the starter wire with the nut. Torque: 9.8 N
m (100 kgf
cm, 7 ft
lbf)
(e) Close the terminal cap cover.
(f) Install the 3 wire harness clamps.
8. INSTALL BATTERY CARRIER Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
9. INSTALL BATTERY TRAY
10. INSTALL BATTERY
11. INSTALL BATTERY CLAMP SUB±ASSY Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt
3.6 N
m (36 kgf
cm, 31 in.
lbf) for nut
5.4 N
m (55 kgf
cm, 48 in.
lbf) for terminal
12. INSTALL RADIATOR SUPPORT OPENING COVER
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190O0±01
19±24
±
STARTING & CHARGINGSTARTER 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)
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