2002 TOYOTA AVENSIS check engine

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.

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.

190O1±01
A79176
±
STARTING & CHARGING GENERATOR 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

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 Temperature68 104 (
F) 020 40(
C) (sec.)
1 19±30
± STARTING & CHARGINGPRE±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 following 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

190O0±01
19±24
±
STARTING & CHARGING STARTER 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)

±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±15
AVENSIS REPAIR MANUAL (RM1018E)
18. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the center pillar of the vehicle or its periphery is damaged, check if \
there is any damage to the
side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with
a new one:
If there are any defects as mentioned below, replace the side airbag sensor with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
19. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the front seat airbag assy and side airbag sensor assy (See page 60±66).
20. AIRBAG SENSOR REAR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
21. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the quarter panel of the vehicle or its periphery is damaged, check if \
there is any damage to the airbag sensor rear. If there are any defects as mentioned below, replace the airbag sensor rear with
a new one:
If there are any defects as mentioned below, replace the airbag sensor rear with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
22. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the curtain shield airbag assy and airbag sensor rear (See page 60±68).
23. SEAT POSITION AIRBAG SENSOR (VEHICLES NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
24. SEAT POSITION AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check for damage to the seat position airbag sensor even if th\
e airbag was not deployed:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.
25. WIRE HARNESS AND CONNECTOR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
26. WIRE HARNESS AND CONNECTOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Check for breaks in all wires of the SRS wire harness, and exposed condu\
ctors.
(c) Check to see if the SRS wire harness connectors are cracked or chipped.
HINT:
The SRS wire harness is integrated with the engine room main wire, instrume\
nt panel wire floor wire, floor
wire No.2 harness assembly.

2801F±02
R03031


F45650
Front (A)
(B)
± TIRE & WHEELWHEEL AND TIRE SYSTEM
28±1
AVENSIS REPAIR MANUAL (RM1018E)
WHEEL AND TIRE SYSTEM
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure:
3ZZ ± FE, 1ZZ ± FE, 1AZ ± FE engine models:
Tire sizeFront
kPa (kgf
cm2, psi)
Rear
kPa (kgf
cm2, psi)
195/65R16 91V, 205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
220 (2.2, 32) *1 240 (2.4, 35) *2
220 (2.2, 32) *1 250 (2.5, 36) *2220 (2.2, 32) *1 240 (2.4, 35) *2
220 (2.2, 32) *1 280 (2.8, 41) *2
1CD ± FTV engine models:
Tire sizeFront
kPa (kgf
cm2, psi)
Rear
kPa (kgf
cm2, psi)
205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
240 (2.4, 35) *1 270 (2.7, 39) *2
240 (2.4, 35) *1 280 (2.8, 41) *2240 (2.4, 35) *1 270 (2.7, 39) *2
240 (2.4, 35) *1 290 (2.9, 42) *2
1AZ ± FSE engine models:
Tire sizeFront
kPa (kgf
cm2, psi)
Rear
kPa (kgf
cm2, psi)
205/55R16 91V:
with 4 or less occupants
with 5 or more occupants
215/45R17 87W:
with 4 or less occupants
with 5 or more occupants220 (2.2, 32) *1 250 (2.5, 36) *2
220 (2.2, 32) *1 270 (2.7, 39) *2
240 (2.4, 35) *1 290 (2.9, 42) *2
240 (2.4, 35) *1 310 (3.1, 45) *2
220 (2.2, 32) *1 250 (2.5, 36) *2
220 (2.2, 32) *1 280 (2.8, 41)*2
240 (2.4, 35) *1 290 (2.9, 42) *2
240 (2.4, 35) *1 330 (3.3, 48) *2
*1: For driving under 160 km/h (100 mph)
*2: For driving at 160 km/h (100 mph) or over
(b) Using a dial indicator, check the runout of tires.
Tire runout: 1.4 mm (0.055 in.) or less
2. ROTATE TIRE
HINT:
If the spare tire is the same as ground tire, perform as ºAº in the
illustration, and if the spare tire is compact tire, perform as ºBº
in the illustration.