charging TOYOTA AVENSIS 2005 Service Repair Manual

022J9±01
02±24
± PREPARATIONSTARTING & CHARGING
AVENSIS REPAIR MANUAL (RM1018E)
STARTING & CHARGING
PREPARATION
SST
09249±63010Torque Wrench AdaptorGENERATOR
ASSY(1AZ±FE/1AZ±FSE)
Recomended Tools
09082±00040TOYOTA Electrical TesterSTARTING SYSTEM(1AZ±FE)
STARTING SYSTEM(1AZ±FSE)
STARTING SYSTEM
(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetSTARTING SYSTEM(1AZ±FE)
STARTING SYSTEM(1AZ±FSE)
STARTING SYSTEM
(1ZZ±FE/3ZZ±FE)
09216±00021Belt Tension GaugeGENERATOR ASSY(1CD±FTV)
Equipment
Slide calipers
Ammeter(A)
Ohmmeter
Radiator cap tester
Torque wrench
Service Wire Harness

02±48
± PREPARATIONHEATER & AIR CONDITIONER
AVENSIS REPAIR MANUAL (RM1018E)
(07117±58080)Quick Disconnect AdapterREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±58090)Quick Disconnect AdapterREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±78050)Refrigerant Charging GaugeREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)

± PREPARATIONHEATER & AIR CONDITIONER
02±49
AVENSIS REPAIR MANUAL (RM1018E)
(07117±88060)Refrigerant Charging HoseREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±88070)Refrigerant Charging HoseREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±88080)Refrigerant Charging HoseREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
07117±48130Vacuum Pump (220 V)W/RECEIVER CONDENSER ASSY
07117±48140Vacuum Pump (240 V)W/RECEIVER CONDENSER ASSY
09870±00015A/C Quick Joint Puller No.1AIR CONDITIONING RADIATOR
ASSY

022L4±02
02±36
± PREPARATIONAUTOMATIC TRANSMISSION / TRANS
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetTRANSMISSION CONTROL CABLE
ASSY
(07117±58060)Refrigerant Drain Service ValveTRANSMISSION CONTROL CABLE
ASSY
(07117±58070)T±JointTRANSMISSION CONTROL CABLE
ASSY
(07117±58080)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±58090)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±78050)Refrigerant Charging GaugeTRANSMISSION CONTROL CABLE
ASSY
(07117±88060)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88070)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88080)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
09023±12700Union Nut Wrench 17mmAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09308±00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09316±60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U241E)

031FQ±01
± SERVICE SPECIFICATIONSINTAKE
03±11
AVENSIS REPAIR MANUAL (RM1018E)
INTAKE
SERVICE DATA
1AZ±FSE:
Vacuum switching valve assy No. 1
Resistance at 20
C (68
F)
33 to 39

1CD±FTV:
Turbocharging pressure
Standard pressure
15 to 45 kPa (0.15 to 0.46 kgf/cm2, 2.2 to 6.5 psi)
Turbo pressure sensor
Voltage 3 (VC) ± 1 (E2)
Voltage drop apply vacuum 13.3 kPa (100 mmHg, 3.94 in.Hg)
apply vacuum 26.7 kPa (200 mmHg, 7.87 in.Hg)
apply vacuum 40.0 kPa (300 mmHg, 11.81 in.Hg)
apply vacuum 57.3 kPa (400 mmHg, 15.75 in.Hg)
apply vacuum 66.7 kPa (500 mmHg, 19.96 in.Hg)
Voltage up applied vacuum 19.6 kPa (0.20 kgf/cm2, 2.84 psi)
applied vacuum 39.2 kPa (0.40 kgf/cm2, 5.69psi)
applied vacuum 58.8 kPa (0.60 kgf/cm2, 8.53psi)
applied vacuum 78.5 kPa (0.80 kgf/cm2, 11.4psi)
applied vacuum 98.0 kPa (1.00 kgf/cm2, 14.2psi)
4.5 to 5.5 V
0.1 to 0.3 V
0.3 to 0.5 V
0.5 to 0.7 V
0. 7 to 0.9 V
0. 9 to 1.0 V
0.1 to 0.4 V
0.4 to 0.7 V
0.7 to 1.0 V
1.0 to 1.3 V
1.3 to 1.6 V

031E7±03
± SERVICE SPECIFICATIONSSTARTING & CHARGING
03±33
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Starter assy x Transaxle housing3737828
Starter wire x Starter assy9.81007
Generator assy x Transverse engine engine mounting bracket2525518
Generator assy x Cylinder block sub±assy5455140
Generator wire x Generator assy9.81007
Lead wire of field coil x Terminal C5.96052 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Wire harness clamp bracket x Starter assy8.48674 in.
lbf
Starter assy x Cylinder block sub±assy3738028
Starter wire x Starter assy9.81007
Battery carrier x Body131319
Battery clamp sub±assy x Body5.05144 in.
lbf
Battery clamp sub±assy x Battery clamp bolt3.63631 in.
lbf
Terminal x Battery5.45548 in.
lbf
Wire harness clamp bracket x Generator assy8.48674 in.
lbf
Generator assy x Cylinder block sub±assy Bolt A
Bolt B52
21530
21438
16
Generator wire x Generator assy9.81007
Lead wire of field coil x Terminal C5.96052 in.
lbf
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Starter x Transaxle Bolt
Terminal 3037
9.8377
10027
7.2
Generator assy x Engine M8
M10
Alternator wire
Wire harness31
47
9.8
5.0320
475
100
5123
34
7
44 in.
lbf
Glow plug assy x Cylinder head Glow plug
Nut12.3
2.2125
229
19 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel RH1031,05076

031E6±01
03±32
± SERVICE SPECIFICATIONSSTARTING & CHARGING
AVENSIS REPAIR MANUAL (RM1018E)
STARTING & CHARGING
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Starter assy
Rated voltage and output power
Specified current
12 V 1.3 kW
85 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Voltage at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage12.9 to 14.9 V
10 A or less
1AZ±FE:
Starter assy
Rated voltage and output power
Specified current
12 V 1.3 kW
85 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Voltage at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage12.9 to 14.9 V
10 A or less
1AZ±FSE:
Starter (1.3 kW type)
Rated voltage and output power
No±load characteristics Current
12 V 1.3 kW
85 A or less at 11.5 V
Starter (1.6 kW type)
Rated voltage and output power
No±load characteristics Current
12 V 1.6 kW
75 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Voltage at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage12.9 to 14.9 V
10 A or less
1CD±FTV:
Starter assy
Rated voltage and output power
Specified current
12 V 2.0 kW
190 A or less at 11.5 V
Starter relay
Specified condition 1 ± 2
3 ± 5
Continuity
No continuity
Battery
Except maintenance±free battery Standard specific gravity
Voltage at 20
C (68
F)
1.25 to 1.29 at 20
C (68
F)
12.5 to 12.9 V
Voltage regulator Regulating voltage
Standard amperage13.2 to 14.8 V
10 A or less
Glow plugs
Resistance at 20
C (68
F)
Approx. 0.72

Glow plug relay
Specified condition 1 ± 2
3 ± 4
No continuity
Continuity

± DIAGNOSTICSSFI SYSTEM (1AZ±FSE)
05±415
AVENSIS REPAIR MANUAL (RM1018E)
DTC P0200 INJECTOR CIRCUIT / OPEN
DTC P0201 INJECTOR CIRCUIT / OPEN ± (CYLINDER 1)
DTC P0202 INJECTOR CIRCUIT / OPEN ± (CYLINDER 2)
DTC P0203 INJECTOR CIRCUIT / OPEN ± (CYLINDER 3)
DTC P0204 INJECTOR CIRCUIT / OPEN ± (CYLINDER 4)
CIRCUIT DESCRIPTION
The Electronic Driver Unit (EDU) has been adopted to operate the injector at high speed. The EDU enables
the injector to drive in high±speed rate under high±pressure fuel condition using its internal DC/DC converter
that provides high voltage and quick±charging system.
The ECM constantly monitors the EDU. If the ECM detects abnormal condition, it will stop the engine.
DTC No.DTC Detection ConditionTrouble Area
P0200
No IJF signals to ECM despite crankshaft rotating 10 times
(1 trip detection logic).
P0200No IJF signals to ECM despite crankshaft rotating 20 times
during cranking (2 trip detection logic).
Open or short in EDU circuit

EDU (Injector driver)
P0201
P0202
P0203
P0204
No IJF signals of each cylinder to ECM 20 times successively
(1 trip detection logic).
(j )

Fuel injector assy

ECM
05CKG±01

A81481
EDU Wiring DiagramCOM3
COM1 COM2
Pressure
Discharge
Valve
Injector
INJ#1
INJ#4INJ#2INJ#3
PRV
GND
EDU Connector
Control
Circuit
DC/DC
Converter
BATTERY
IJT#1
IJT#4
IJT#2
IJT#3PRDIJF
ECM
Maximum 150 V
Confirmation
Pulse Command
Pulse
Warning:
Terminal J, I, H, K, L, M, N and S are high voltage
E5
E4
Maximum 150 V
05±604
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0200INJECTOR CIRCUIT / OPEN
HINT:

For more information on the EDU, see page 05±517.

If P0200 are present, Use the diagnostic trouble code matrix for fuel sy\
stem, see page 05±517.
CIRCUIT DESCRIPTION
The EDU has been adopted to drive the injector at high speeds. The EDU has \
realized high±speed driving
under high fuel pressure conditions using the DC/DC converter that provides a\
high±voltage, quick±charging
system.
Soon after the EDU receives an injection command signal (IJT) from the\
ECM, the EDU responds to the com-
mand with injector injection confirmation signal (IJF) when the current is\
applied to the injector.
05CPR±01

05±654
±
DIAGNOSTICS ECD SYSTEM(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
4INSPECT CHARGING SYSTEM (See page 19±26)
GO
CHECK DTC OUTPUT RECUR (DTC P0622 OUTPUT AGAIN)
HINT:
After clearing the DTC, start the engine and let it idle for 10 seconds, and \
then confirm P0622 is not set again.