2003 TOYOTA AVENSIS alternator

APPENDIX
Vehicle GradeBody Type
Min. Running Ground Clearance mm (in.)
Angle of Approach degrees
Angle of Departure degrees
Item Area
Model Code
Overall Length mm (in.)
Width mm (in.)
Height mm (in.)
Wheel Base mm (in.)
Tread Front mm (in.)
Rear mm (in.)
Room Front mm (in.)
Rear mm (in.)
Overhang
Curb Weight
Gross Vehicle Weight Front kg (lb)
Rear kg (lb)
Total kg (lb)
Front kg (lb)
Rear kg (lb)
Total kg (lb)
Fuel Tank Capacity (Imp.gal.)
Luggage Compartment Capacity m
3 (cu.ft.)
Max. Speed km / h (mph)
Max. Cruising Speed km / h (mph)
Acceleration
Max. Permissible
Speed
Min. Turning Radius 0 to 100 km / h sec.
0 to 400 m sec.
1st Gear km / h (mph)
2nd Gear km
/h (mph)
3rd Gear km / h (mph)
4th Gear km / h (mph)
Tire m (ft.)
Body m (ft.)
Engine Type
Valve Mechanism
Bore x Stroke mm (in.)
Displacement cm
3 (cu.in.)
Compression Ratio
Carburetor Type or Injection Pump Type (Diesel)Research Octane No. or Cetane No. (Diesel)
Max. Output (EEC) kW / rpm
Max. Torque (EEC) N
.m / rpm
Battery Capacity (5HR) Voltage & Amp. hr.
Alternator Output Watts
Starter Output kW
Clutch Type
Transaxle Type
Transmission Gear
Ratio
Counter Gear Ratio
Differential Gear Ratio (Final)
Brake Type
Parking Brake Type
Brake Booster Type and Size in.
Proportioning Valve Type
Suspension Type
Stabilizer Bar
Steering Gear Type
Steering Gear Ratio (Overall)
Power Steering Type In First
In Second
In Third
In Fourth
In Fifth
In Reverse
Front
Rear
Front
Rear
Front
Rear
5
10
15
20
25
30
35
40
45
50
55
60
65
70
Major Dimension & Vehicle Weights
Performance
Engine
Engine
Chassis Electric
EUROPE
5-Door Wagon
MID ELEGANT
Length mm (in.)
Width mm (in.)
Height mm (in.) ENTRY
AP-18
AZT250R-AWPGHW AZT250L-AWPGHW CDT250R-AWMNYW CDT250L-AWMNYW
4700 (185.0) 4700 (185.0)4700 (185.0)4700 (185.0)
1760 (69.3) 1760 (69.3)1760 (69.3)1760 (69.3)
1525 (60.0) 1525 (60.0)1525 (60.0)1525 (60.0)
2700 (106.3) 2700 (106.3)2700 (106.3)2700 (106.3)
1506 (59.3) 1506 (59.3)1506 (59.3)1506 (59.3)
1510 (59.4) 1510 (59.4)1510 (59.4)1510 (59.4)
2090 (82.3) 2090 (82.3)2090 (82.3)2090 (82.3)
1485 (58.5) 1485 (58.5)1485 (58.5)1485 (58.5)
1210 (47.6), 1160 (45.7)*
11210 (47.6), 1160 (45.7)*11210 (47.6), 1160 (45.7)*11210 (47.6), 1160 (45.7)*1
910 (35.8) 910 (35.8)910 (35.8)910 (35.8)
1095 (43.1) 1095 (43.1)1095 (43.1)1095 (43.1)
135 (5.3), 155 (6.1)*
2135 (5.3), 155 (6.1)*2135 (5.3), 155 (6.1)*2135 (5.3), 155 (6.1)*2
13.1
, 14.5
*213.1
, 14.5
*213.1
, 14.5
*213.1
, 14.5
*2
18
, 19.2
*218
, 19.2
*218
, 19.2
*218
, 19.2
*2
800 - 825 (1764 - 1819) 800 - 825 (1764 - 1819) 850 - 900 (1874 - 1984) 850 - 900 (1874 - 1984)
585 - 595 (1290 - 1312) 585 - 595 (1290 - 1312) 580 - 590 (1279 - 1301) 580 - 590 (1279 - 1301)
1385 - 1420 (3054 - 3131) 1385 - 1420 (3054 - 3131) 1430 - 1490 (3153 - 3285) 1430 - 1490 (3153 - 3285) 915 (2017) 915 (2017)985 (2172)985 (2172)
980 (2161) 980 (2161)985 (2172)985 (2172)
1895 (4178) 1895 (4178)1970 (4344)1970 (4344)
60 (15.9, 13.2) 60 (15.9, 13.2)60 (15.9, 13.2)60 (15.9, 13.2)
0.520 (18.4) 0.520 (18.4)0.520 (18.4)0.520 (18.4)
190 (118) 190 (118)190 (118)190 (118)
ÐÐÐÐ
11.3 11.311.411.4
17.7 17.717.817.8
63 (39) 63 (39)45 (27)45 (27)
114 (71) 114 (71) 84 (52)84 (52)
177 (110) 177 (110) 128 (79)128 (79)
Ð Ð176 (109) 176 (109)
5.6 (18.4) 5.6 (18.4)5.6 (18.4)5.6 (18.4)
5.995 (19.7) 5.995 (19.7)5.995 (19.7)5.995 (19.7)
1AZ-FSE 1AZ-FSE1CD-FTV 1CD-FTV
16-Valve, DOHC 16-Valve, DOHC16-Valve, DOHC16-Valve, DOHC
86.0 x 86.0 (3.39 x 3.39) 86.0 x 86.0 (3.39 x 3.39) 82.2 x 94.0 (3.24 x 3.70) 82.2 x 94.0 (3.24 x 3.70)
1998 (121.9) 1998 (121.9)1995 (121.7)1995 (121.7)
11.0 11.017.8 17.8
EFI EFICommon-Rail Type Common-Rail Type
95 or higher 95 or higher48 or higher48 or higher
108 / 5700 108 / 5700 85 / 360085 / 3600
196 / 4000 196 / 4000280 / 2000 - 2200 280 / 2000 - 2200
12 - 48 12 - 4812 - 6012 - 60
1200 120012001200
1.6 1.62.02.0
Ð ÐDry, Single Plate Dry, Single Plate
U241E*
4U241E*4E357 E357
3.943 3.9433.5383.538
2.197 2.1971.9131.913
1.413 1.4131.2581.258
1.020 1.0200.9180.918
Ð Ð0.690 0.690
3.145 3.1453.5833.583
ÐÐÐÐ
2.923 2.9233.6843.684
Ventilated Disc Ventilated DiscVentilated DiscVentilated Disc
Solid Disc Solid DiscSolid DiscSolid Disc
Drum DrumDrumDrum
Tandem 8º + 9º Tandem 8º + 9ºTandem 8º + 9ºTandem 8º + 9º
ÐÐÐÐ
MacPherson Strut. MacPherson Strut.MacPherson Strut.MacPherson Strut.
Double Wishbone Double WishboneDouble WishboneDouble Wishbone
STD STDSTDSTD
STD STDSTDSTD
Rack and Pinion Rack and PinionRack and PinionRack and Pinion
16.1 16.116.116.1
Integral Type Integral TypeIntegral TypeIntegral Type
*
1: With Sun Roof *4: Snow Mord Type
*2: Rough Road Pack
*3: Option
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010B9±11
±
INTRODUCTION TERMS
01±37
AVENSIS REPAIR MANUAL (RM1018E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CANController Area Network
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
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010BA±14
01±42
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI/INJ)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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031E7±03
±
SERVICE SPECIFICATIONS STARTING & 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
347
44 in.
lbf
Glow plug assy x Cylinder head Glow plug
Nut12.32.2125229
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
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140DD±03
A57063
Measure Point for Belt
Deflection and Tension
Alternator
Crankshaft Compressor
P/S P/S
Alternator Crankshaft
A/C equipped
A/C not equipped
A61173
B
A
14±266
±
ENGINE MECHANICALENGINE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
ENGINE(1CD±FTV)
INSPECTION
1.INSPECT COOLANT (See page 16±37)
2.INSPECT ENGINE OIL (See page 17±20)
3.INSPECT BATTERY (See page 19±26)
4. INSPECT AIR CLEANER FILTER ELEMENT SUB±ASSY 5. INSPECT DRIVE BELT
(a) Inspect vane pump V belt.(1) Measure the belt deflection
Pressing force: 98 N
m (10 kgf 22 lbf)
New belt
mm (in.)Used belt mm (in.)
A/C equipped9.5 to 11.5
(0.37 to 0.45)12.5 to 15.5
(0.49 to 0.61)
A/C not equipped10 to 12
(0.39 to 0.47)14 to 17
(0.55 to 0.67)
(2) Measure the belt tension
New belt
N (kgf, lbf)Used belt
N (kgf, lbf)
A/C equipped519 to 755
(53 to 77, 117 to 170)196 to 392
(20 to 40, 44 to 88)
A/C not equipped686 to 784
(70 to 80, 154 to 176)294 to 441
(30 to 45, 66 to 99)
NOTICE:

Check the drive belt deflection at the specified point.

When installing a new belt, set its tension value as
specified.

When inspecting the belt which is used over 5 min-
utes, apply the specifications of ºUsed Belt.º

When reinstalling the belt which is used over 5 min-
utes, adjust its deflection and tension to the medium
value in each specification of ºUsed Belt.º

V±ribbed belt tension and deflection should be
checked after 2 revolutions of engine cranking.

When using a belt tension gauge, confirm the accura-
cy by using a master gauge first.
(b) Inspect generator V belt. (1) Check that the tension indicator is within range A onthe auto tensioner scale.
If the tension is not within the A range, replace the belt with a
new one.
HINT:
When replacing the drive belt with a new one, the belt tension
should be within the B range.
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010BJ±01
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TERMS (1ZZ±FE/3ZZ±FE)
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector
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010BK±01
01±12
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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02148±01
±
PREPARATION STARTING & CHARGING
02±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
STARTING & CHARGING
PREPARATION
SST
09286±46011Injection Pump Spline Shaft
PullerGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
09820±63010Alternator Pulley Set Nut Wrench
SetGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09820±06010)Alternator Rotor Shaft WrenchGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09820±06020)Alternator Pulley Set Nut 22 mm
WrenchGENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
Recomended Tools
09011±12291Socket Wrench for 29 mm .GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
09082±00040TOYOTA Electrical TesterSTARTER ASSY
(1ZZ±FE/3ZZ±FE)
GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
(09083±00150)Test Lead SetSTARTER ASSY
(1ZZ±FE/3ZZ±FE)
GENERATOR ASSY
(1ZZ±FE/3ZZ±FE)
Equipment
Ohmmeter
Sandpaper
V±block
Dial indicator
Vernier calipers
Plastic hammer
Torque wrench
Wooden block
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