TOYOTA AVENSIS 2003 Service Repair Manual

190NH±01
A78485
(a)
Terminal
Cap Cover
(b)
A78486
±
STARTING & CHARGINGSTARTER 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
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190NU±01
A78629
Terminal CTerminal 50
A78630Disconnect
A78631
Disconnect
19±8
±
STARTING & CHARGING STARTING 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 asshown 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 Cwith 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 switchbody. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.
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A78632
Terminal 30
Terminal 50
Ammeter
B16200
±
STARTING & CHARGING STARTING 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. Makesure 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 betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
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190NR±01
A78629
Terminal CTerminal 50
A78630Disconnect
A78631
Disconnect
19±10
±
STARTING & CHARGING STARTING 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 asshown 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 Cwith 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 switchbody. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.
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A78632
Terminal 30
Terminal 50
Ammeter
B16200
±
STARTING & CHARGING STARTING 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. Makesure 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 betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Applying battery voltage terminals 1 and 2)
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190NL±01
A78633
Terminal CTerminal 50
A78634Disconnect
A78635
Disconnect
19±22
±
STARTING & CHARGING STARTING 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 asshown 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 terminalC 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 switchbody. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.
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A78637
Terminal 30
Terminal 50
Ammeter
B16200
±
STARTING & CHARGING STARTING 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. Makesure 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 betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
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190NO±01
A82615Terminal CTerminal 50
A82616Terminal C Terminal 50
A82617
Terminal C Terminal 50
±
STARTING & CHARGING STARTING 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 asshown 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 Cwith 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 switchbody. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the magnetic
switch.
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A82618Terminal C Terminal 50
B16200
19±2
±
STARTING & CHARGING STARTING 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. Makesure 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 betweeneach terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuIty
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
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2600M±04
F13686
C80880
F13683
F44622
26±10
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:

COMPONENTS: See page 26±2

This procedure is provided for the overhaul on the LH side. Overhaul the oth\
er side by the same proce-
dure as the LH side.
1. REMOVE FRONT WHEEL
2. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the stabilizer bar link fromthe shock absorber.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Remove the bolt, disconnect the front flexible hose and speed sensor front LH.
(b) Remove the 2 nuts and bolts on the lower side of the shock absorber.
(c) Remove the 3 nuts on the upper side of the shock absorb- er.
(d) Remove the shock absorber with the coil spring.
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