TOYOTA AVENSIS 2005 Service Repair Manual

190VD−01
A55650
SST (A)
SST (B)
A92421
Rotor Shaft
SST (A)
A57794
SST (B)
Turn
A81164
− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)19−11
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
OVERHAUL
1. REMOVE GENERATOR W/CLUTCH PULLEY
(a) Remove the generator pulley cap.
(b) Set SST (A) and (B).
SST 09820−63020
(c) Clamp SST (A) in a vise.
(d) Set the generator to SST.
NOTICE:
At this time, make sure that the generator and SST are per-
pendicular to one another.
(e) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(f) To loosen the pulley, turn SST (B) in the direction shown
in the illustration.
(g) Remove the generator from SST.
(h) Remove the pulley from the rotor shaft.
2. REMOVE GENERATOR REAR END COVER
(a) Remove the 3 nuts and end cover.
(b) Remove the terminal insulator.

A81147
A81148
SST
A92425
A81902
Lock Turn
B12264
Ohmmeter 19−12
− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
3. REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Remove the 2 screws, then remove the generator brush
holder.
4. REMOVE GENERATOR COIL ASSY
(a) Remove the 4 bolts.
(b) Using SST, remove the coil assembly.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04020, 09954−04010, 09955−04071,
09957−04010, 09958−04011)
5. REMOVE GENERATOR ROTOR ASSY
6. INSPECT GENERATOR W/CLUTCH PULLEY
(a) Check that the pulley is locked when it is turned clock-
wise, and that the pulley rotates smoothly when it is
turned counterclockwise.
7. INSPECT GENERATOR ROTOR ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the slip rings.
Standard resistance: 2.3 to 2.7
at 20˚C (68˚F)
If the resistance is not as specified, replace the rotor.

B12265
Ohmmeter
B12266
A79305
Length
B16375
− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)19−13
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the slip ring and rotor.
Standard: 1 M
or higher
If the resistance is not as specified, replace the rotor.
(c) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(d) Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the rotor.
8. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Using vernier calipers, measure the exposed brush
length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 4.5 mm (0.177 in.)
If the exposed length is less than minimum, replace the brushes
and brush holder assembly.
9. INSPECT GENERATOR ROTOR BEARING
(a) Check that the bearing is not rough or worn.
If necessary, replace the rotor.
10. INSPECT GENERATOR DRIVE END FRAME BEARING
(a) Check that the bearing is not rough or worn.
If necessary, replace the bearing.
11. REMOVE GENERATOR DRIVE END FRAME BEARING
(a) Remove the 4 screws, bearing retainer.

B16518
SST
B16515
SST
B16368
Pulley
B16521
A81671
Deep Socket
Wrench 21
19−14− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(b) Using SST and a hammer, tap out the bearing.
SST 09950−60010 (09951−00250), 09950−70010
(09951−07100)
12. INSTALL GENERATOR DRIVE END FRAME BEARING
(a) Using SST and a press, press in a new bearing.
SST 09950−60010 (09951−00470), 09950−70010
(09951−07100)
(b) Install the bearing retainer with the 4 screws.
Torque: 2.3 Nm (23 kgfcm, 20 in.lbf)
13. INSTALL GENERATOR ROTOR ASSY
(a) Place the drive end frame on the pulley.
(b) Install the rotor to the drive end frame.
14. INSTALL GENERATOR COIL ASSY
(a) Place the generator washer on the rotor.
(b) Using a 21 mm deep socket wrench and press, press in
the coil carefully.

A81148
A79315
Pin (
1.0 mm (0.039 in.))
A81672
Pin (
1.0 mm (0.039 in.))
A81146
A81164
− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)19−15
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(c) Install the coil assembly with the 4 bolts.
Torque: 5.8 Nm (59 kgfcm, 51 in.lbf)
15. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) While pushing the 2 brushes to inside the brush holder,
insert a pin (1.0 mm (0.039 in.)) into the brush holder
hole.
(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 Nm (18 kgfcm, 16 in.lbf)
(c) Pull out the pin (1.0 mm (0.039 in.)) from the generator
brush holder.
16. INSTALL GENERATOR REAR END COVER
(a) Install the terminal insulator.
NOTICE:
Be careful of the terminal insulator installation direction.
(b) Install the end cover with the 3 nuts.
Torque: 4.6 Nm (47 kgfcm, 41 in.lbf)

A55650
SST (A)
SST (B)
A92421
Rotor Shaft
SST (A)
A57803
SST (B)
Turn
19−16− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
17. INSTALL GENERATOR W/CLUTCH PULLEY
(a) Temporarily install the pulley to the rotor shaft.
(b) Set SST (A) and (B).
SST 09820−63020
(c) Clamp SST (A) in a vise.
(d) Set the generator to SST.
NOTICE:
At this time, make sure that the generator and SST are per-
pendicular to one another.
(e) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(f) To torque the pulley, turn SST (B) in the direction shown
in the illustration.
Torque: 111 Nm (1,132 kgfcm, 82 ftlbf)
HINT:
Use a torque wrench with the fulcrum length of 50 cm (19.69
in.).
(g) Remove the generator from SST.
(h) Check that the generator pulley rotates smoothly.
(i) Install the generator pulley cap.

141NU−01
A09477
A09488
A09492
A09494
Plastigage
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−43
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
OVERHAUL
1. INSPECT CONNECTING ROD THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the connecting rod back and forth.
Standard thrust clearance:
0.08 to 0.40 mm (0.0031 to 0.0157 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE
(a) Check the match marks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing attached to the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pits and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Lay a strip of Plastigage across the crank pin.

A09514
Front Mark
(Protrusion)
A09493
90_
90_
A09490
Front
Painted Mark
A09495
14−44− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(g) Match the numbered connecting rod cap with the con-
necting rod.
(h) Install the connecting rod cap with the front mark facing
forward.
(i) Apply a light coat of engine oil to the threads and under-
heads of the connecting rod cap bolts.
(j) Install and alternately tighten the 2 cap bolts in several
steps.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
If any of the cap bolts does not meet the specified torque, re-
place the connecting rod cap bolts.
(k) Mark the front of the cap bolt with paint.
(l) Retighten the cap bolts by 90_as illustrated.
(m) Check that the painted mark is now at a 90_angle to the
front.
NOTICE:
Do not turn the crankshaft.
(n) Remove the 2 bolts, connecting rod cap and lower bear-
ing.
(o) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 to 0.056 mm (0.0015 to 0.0022 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

A09472
No. 1
No. 2
No. 3
No. 4
Mark
0,1 or 2Mark
1, 2, 3, 4 or 5Mark
1, 2 or 3
A56037
Ridge Reamer
− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)14−45
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
(p) If using the standard bearing, replace it with one having
the same number. If the number of the bearing cannot be
determined, find the correct number of the bearing by ad-
ding together the numbers imprinted on the crankshaft
and connecting rod cap, then select the bearing with the
same number as the total. There are 5 sizes of standard
bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly.
Connecting Rod CapCrankshaftUse Bearing
101
112
123
202
213
224
303
314
325
HINT:
EXAMPLE: Connecting rod cap ”2” + Crankshaft ”1”
= Total number 3 (Use bearing ”3”)
Connecting rod big end inside diameter:
Mark ”1”53.500 to 53.506 mm (2.1063 to 2.1065 in.)
Mark ”2”53.506 to 53.512 mm (2.1065 to 2.1068 in.)
Mark ”3”53.512 to 53.518 mm (2.1068 to 2.1070 in.)
Crankshaft crank pin diameter:
Mark ”0”50.494 to 50.500 mm (1.9880 to 1.9882 in.)
Mark ”1”50.488 to 50.494 mm (1.9877 to 1.9880 in.)
Mark ”2”50.482 to 50.488 mm (1.9875 to 1.9877 in.)
Standard size bearing center wall thickness:
Mark ”1”1.478 to 1.481 mm (0.0582 to 0.0583 in.)
Mark ”2”1.481 to 1.484 mm (0.0583 to 0.0584 in.)
Mark ”3”1.484 to 1.487 mm (0.0584 to 0.0585 in.)
Mark ”4”1.487 to 1.490 mm (0.0585 to 0.0587 in.)
Mark ”5”1.490 to 1.493 mm (0.0587 to 0.0588 in.)
(q) Completely remove the Plastigage.
3. REMOVE PISTON SUB−ASSY W/CONNECTING ROD
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
SKeep the bearing, connecting rod and cap together.
SArrange the piston and connecting rod assemblies in the
correct order.
4. REMOVE CONNECTING ROD BEARING

A09496
A09497
A08026
A85943
14−46− ENGINE MECHANICALCYLINDER BLOCK ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
5. INSPECT CRANKSHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.040 to 0.300 mm (0.0016 to 0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washer as a set.
Thrust washer thickness:
Standard2.680 to 2.730 mm (0.1055 to 0.1075 in.)
Oversize 0.1252.743 to 2.793 mm (0.1080 to 0.1100 in.)
Oversize 0.2502.805 to 2.855 mm (0.1104 to 0.1124 in.)
6. REMOVE CRANKSHAFT
(a) Uniformly loosen and remove the 10 main bearing cap
bolts.
(b) Using the removed main bearing cap bolts, wiggle the cap
back and forth, then remove the 5 main bearing caps, 5
lower bearings and 2 lower thrust washers (the No. 3 main
bearing cap only).
HINT:
SKeep the lower bearing and main bearing cap together.
SArrange the main bearing caps and lower thrust washers
in the correct order.
(c) Lift the crankshaft out.
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
7. REMOVE SUB−ASSY OIL NOZZLE NO.1
(a) Remove the 4 bolts and 4 oil nozzles.