Page 969 of 2234

B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter
Battery Ammeter
19±6
±
STARTING & CHARGING CHARGING 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 engin\
e 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 warn\
ing 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 generatorand 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 thereading 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 genera\
tor.
If the battery is fully charged, the indication will sometimes be less t\
han standard amperage.
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190NK±01
A78515
A78516
A77903
(a)
(a)
(b)
(b)
(b)
A77904
(f)
(f)
(e)
(d)
Terminal Cap
19±20
±
STARTING & CHARGINGGENERATOR ASSY(1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
GENERATOR ASSY(1AZ±FE/1AZ±FSE)
REPLACEMENT
1.REMOVE ENGINE UNDER COVER LH
(a)Remove the 6 screws and 5 clips, and then remove the engine under cover.
2.REMOVE ENGINE UNDER COVER RH
(a)Remove the 6 screws and the 3 clips, and then remove the engine under cover.
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 SST 09249±63010
HINT:
1AZ±FE: 14±105
1AZ±FSE: 14±185
6. REMOVE GENERATOR ASSY
(a) Disconnect the 2 heated oxygen sensor connectors. (1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(b) Remove the 2 connector clamps of the heated oxygen sensor and the wire harness clamp.
(1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(c) Remove the terminal cap.
(d) Remove the nut and disconnect the generator wire.
(e) Disconnect the generator connector.
(f) Remove the 2 wire harness clamps.
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Page 971 of 2234

A77905
A77906
A77905
A
B
±
STARTING & CHARGING GENERATOR ASSY (1AZ±FE/1AZ±FSE)
19±21
AVENSIS REPAIR MANUAL (RM1018E)
(g) Remove the 2 bolts, and then remove the generator.
(h) Remove the bolt, and then remove the wire harness
clamp bracket.
7. INSTALL GENERATOR ASSY
(a) Install the wire harness clamp bracket wire the bolt. Torque: 8.4 N m (86 kgf cm, 74 in. lbf)
(b) Install the generator the 2 bolts. Torque:
52 Nm (530 kgf cm, 38 ftlbf) for bolt A
21 N m (214 kgf cm, 16 ftlbf) for bolt B
(c) Install the 2 wire harness clamps.
(d) Connect the generator connector.
(e) Install the generator wire with the nut. Torque: 9.8 N m (100 kgf cm, 7 ftlbf)
(f) Install the terminal cap.
(g) Install the 2 connector clamps of the heated oxygen sen- sor and the wire harness clamp.
(1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
(h) Connect the 2 heated oxygen sensor connectors. (1AZ±FE (Unleaded Gasoline) or 1AZ±FSE)
8. INSTALL FAN AND GENERATOR V BELT
SST 09249±63010
HINT:
1AZ±FE: 14±105
1AZ±FSE: 14±185
9. INSTALL ENGINE ROOM COVER SIDE
10. INSTALL RADIATOR SUPPORT OPENING COVER
11. INSTALL ENGINE UNDER COVER RH
12. INSTALL ENGINE UNDER COVER LH
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190O1±01
A79176
±
STARTING & CHARGINGGENERATOR 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 Nm (320 kgfcm, 23 ftlbf) for M8
47 Nm (475 kgfcm, 34 ftlbf) for M10
9.8 Nm (100 kgfcm, 7 ft lbf) for Generator wire
5.0 Nm (51 kgf cm, 44 ftlbf) 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 kgfcm, 76 ft lbf)
18. CHECK FOR EXHAUST GAS LEAKS
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Page 973 of 2234

190NI±01
A78487
(a)
(d)
(e)
(c)
Terminal Cap No. 2
A78488
A78488
A
B
±
STARTING & CHARGINGGENERATOR 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 Nm (255 kgfcm, 18 ftlbf) for bolt A
54 Nm (551 kgfcm, 40 ftlbf) 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 kgfcm, 7 ftlbf)
(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
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Page 974 of 2234
190O2±01
A79177
±
STARTING & CHARGING GLOW PLUG ASSY (1CD±FTV)
19±33
AVENSIS REPAIR MANUAL (RM1018E)
GLOW PLUG ASSY (1CD±FTV)
REPLACEMENT
1. REMOVE ENGINE COVER NO.1
(a) Remove the 5 nuts and the engine cover.
2. REMOVE GLOW PLUG ASSY
(a) Remove the 5 grommets.
(b) Remove the 5 nuts and the glow plug connector.
(c) Remove the 4 glow plugs.
3. INSTALL GLOW PLUG ASSY Torque:
12.3 N m (125 kgf cm, 9 ftlbf) for glow plug
2.2 N m (22 kgf cm, 19 in. lbf) for nut
4. INSTALL ENGINE COVER NO.1
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
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Page 975 of 2234
![TOYOTA AVENSIS 2003 Service Repair Manual 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 Temperature 68 TOYOTA AVENSIS 2003 Service Repair Manual 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 Temperature 68](/manual-img/14/57444/w960_57444-974.png)
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 Temperature 68 104 (
F)
020 40(
C)
(sec.)
1
19±30
±
STARTING & CHARGING PRE±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 followi\
ng 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
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Page 976 of 2234
B08263
OhmmeterContinuity
±
STARTING & CHARGING PRE±HEATING SYSTEM (1CD±FTV)
19±31
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT GLOW PLUGS
(a) Using an ohmmeter, check that there is continuity be-
tween the glow plug terminal and ground.
Standard resistance: Approx. 0.72 at 20 C (68 F)
NOTICE:
Be careful not to damage the glow plug pipes as it
could cause an open circuit or shorten life of the glow
plugs.
Avoid getting oil and gasoline on the glow plug when
cleaning.
Wipe up any oil on the terminal and Bakelite washer
with a dry cloth if they are stained with oil during in-
spection.
Be careful not to apply more than 11 V to the glow plug
as it could cause an open circuit.
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