TOYOTA AVENSIS 2005 Service Repair Manual

±
COOLING WATER PUMP ASSY(1CD±FTV)
16±49
AVENSIS REPAIR MANUAL (RM1018E)
41.SET NO. 1 CYLINDER TO TDC/COMPRESSION
SST09960±10010 (09962±01000, 09963±01000)
42.INSTALL TIMING BELT(See page 14±307)
43.CHECK VALVE TIMING(See page 14±307)
44.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
45.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
46.INSTALL TIMING BELT GUIDE(See page 14±307)
47.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
48.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
49.INSTALL IDLER PULLEY SUB±ASSY(See page 11±69)
50.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
51.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
52.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
53.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
54.INSTALL INJECTOR DRIVER(See page 11±69)
55. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
56. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
57.ADD ENGINE COOLANT(See page 16±44)
58.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
59.CHECK FOR FUEL LEAKS(See page 11±60)

190NI±01
A78487
(a)
(d)
(e)
(c)
Terminal Cap No. 2
A78488
A78488
A
B
±
STARTING & CHARGING GENERATOR 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

190NQ±01
A81052


A82936
Type A
Type B
BlueWhite
Red Green DarkClear or
light yellow
B00543
± STARTING & CHARGINGCHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
19±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
(1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and
check the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicle
or since the engine was stopped, turn the ignition switch
and the electrical system (headlight, blower motor, rear
defogger etc.) to the on position for 60 seconds. This will
remove the surface charge on the battery.
(b) Turn off the ignition switch and the electrical systems.
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage: 12.5 to 12.9 V at 20C (68F)
HINT:
If the voltage is less than specification, charge the battery.
(d) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
3. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loosened or corroded.
(b) Check the fusible links, high±current fuses and regular fuses.
4. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:

If any defect found, replace the drive belt.

Cracks on the rib side of a belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be
replaced.

B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter 19±6
± STARTING & CHARGINGCHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engine is running.
7. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine and check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-
ter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the generator
and connect it to the negative (±) lead of the amme-
ter.
(2) Connect the positive (+) lead of the ammeter to ter-
minal B of the generator
(3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (±) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm, check the
reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
HINT:

If the voltmeter reading is more than standard voltage, re-
place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights and turn the heater blower
switch to the ºHIº position.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage, repair the generator.

If the battery is fully charged, the indication will sometimes be less than standard amperage.

190NP±01
19±4
± STARTING & CHARGINGCHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
CHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
PRECAUTION
1. Check that the battery cables are connected to the correct terminals.
2. Disconnect the battery cables when the battery is given a quick charge.
3. Do not perform tests with a high voltage insulation resistance tester.
4. Never disconnect the battery while the engine is running.
5. Check that the charging cable is tightened on terminal B of the generator and the fuse box.

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

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)

1807L±01
A77896
(a)(b)
(c)
(d)
±
IGNITION CRANKSHAFT POSITION
SENSOR(1AZ±FE/1AZ±FSE)18±17
AVENSIS REPAIR MANUAL (RM1018E)
CRANKSHAFT POSITION SENSOR(1AZ±FE/1AZ±FSE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER LH (See page 19±20)
2.REMOVE ENGINE UNDER COVER RH (See page 19±20)
3.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26)
4.REMOVE ENGINE ROOM COVER SIDE (See page 10±26)
5.REMOVE FAN AND GENERATOR V BELT
6.REMOVE GENERATOR ASSY (See page 19±20)
SST09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
7.REMOVE CRANKSHAFT POSITION SENSOR
(a)Disconnect the crankshaft position sensor connector.
(b)Remove the wire harness of the crankshaft position sen-sor from the wire harness clamp bracket.
(c)Remove the connector clamp.
(d)Remove the wire harness clamp.
(e)Remove the bolt, and then remove the crankshaft posi-
tion sensor.
8.INSTALL CRANKSHAFT POSITION SENSOR
(a)Apply a light coat of engine oil to the O±ring on the crankshaft posi\
tion sensor.
(b)Install the crankshaft position sensor with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
(c)Install the wire harness clamp.
(d)Install the connector clamp.
(e)Install the wire harness of the crankshaft position sensor to the the wi\
re harness clamp bracket.
(f)Connect the crankshaft position sensor connector.
9.INSTALL GENERATOR ASSY (See page 19±20)
10. INSTALL FAN AND GENERATOR V BELT SST 09249±63010
HINT:

1AZ±FE: 14±105

1AZ±FSE: 14±185
11. INSTALL ENGINE ROOM COVER SIDE
12. INSTALL RADIATOR SUPPORT OPENING COVER
13. INSTALL ENGINE UNDER COVER RH
14. INSTALL ENGINE UNDER COVER LH

1807K±01
A77895
18±16
±
IGNITION CAMSHAFT POSITION SENSOR(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
CAMSHAFT POSITION SENSOR(1AZ±FE/1AZ±FSE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 10±26) 2. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the camshaft position sensor connector.
(b) Remove the bolt, and then remove the camshaft positionsensor.
3. INSTALL CAMSHAFT POSITION SENSOR
(a) Apply a light coat of engine oil to the O±ring on the camshaft positi\
on sensor.
(b) Install the camshaft position sensor with the bolt. Torque: 9.0 N
m (92 kgf
cm, 79 in.
lbf)
(c) Connect the camshaft position sensor connector.
4. INSTALL RADIATOR SUPPORT OPENING COVER