2003 TOYOTA AVENSIS alternator

190AA±01
A62753
SST
1 ± BSST
1 ± A
A62754SST 2
A62755
SST
1 ± A
A62756
SST
1 ± A
SST
1 ± B
19±10
±
STARTING & CHARGING GENERATOR ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE GENERATOR PULLEY SST 09820±63010 (09820±06010, 09820±06020)
HINT:
SST1 ± A, B09820±06010
SST209820±06020
(a) Hold SST 1 ± A with a torque wrench, and tighten SST 1 ± B clockwise to the specified torque.
Torque: 39 N
m (398 kgf
cm, 29 ft
lbf)
NOTICE:
Check that SST is secured to the rotor shaft.
(b) Mount SST 2 in a vise.
(c) Insert SST 1 ± A, B into SST 2, and attach the pulley nut to SST 2.
(d) To loosen the pulley nut, turn SST 1 ± A in the direction shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one±half of a turn.
(e) Remove the alternator form SST 2.
(f) Turn SST 1 ± B, and remove SST 1 ± A, B.
(g) Remove the pulley nut and pulley.
http://vnx.su

A62753
SST
1 ± BSST
1 ± A
A62754SST 2
A62765
SST
1 ± A
19±14
±
STARTING & CHARGING GENERATOR ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(b) Install the rear end cover with the 2 nuts. Torque: 4.4 N
m (45 kgf
cm, 39 in.
lbf)
(c) Install the terminal plate with the screw and nut.
Torque:
Bolt 3.9 N
m (40 kgf
cm, 35 in.
lbf)
Nut 4.4 N
m (45 kgf
cm, 39 in.
lbf)
(d) Install the terminal insulator withe the nut.
Torque: 4.1 N
m (42 kgf
cm, 36 in.
lbf)
14. INSTALL GENERATOR PULLEY SST 09820±63010 (09820±06010, 09820±06020)
HINT:
SST1 ± A, B09820±06010
SST209820±06020
(a) Install the pulley to the rotor shaft by tightening the pulley nut by hand.
(b) Hold SST 1 ± A with a torque wrench, and tighten SST 1 ± B clockwise to the specified torque.
Torque: 39 N
m (398 kgf
cm, 29 ft
lbf)
NOTICE:
Check that SST is secured to the pulley shaft.
(c) Mount SST 2 in a vise.
(d) Insert SST 1 ± A, B into SST 2, and attach the pulley nut to SST 2.
(e) Tighten the pulley nut, turn SST 1 ± A in the direction shown in the illustration.
Torque: 111 N
m (1,132 kgf
cm, 82 ft
lbf)
(f) Remove the alternator form SST 2.
http://vnx.su

I35431
Burner Motor
Glow Plug
Surface Sensor
Temp. Control Sensor
Flame Sensor 13
Power
Heater
ECU
Connector B Terminal L
of Alternator
Battery
Metering Pump
Fuse (20 A)
Vehicle Side
SW
14
9
12
5
6
3
4
1
2 R
BR
B±R
G
L±Y L
Y
L±W 5
1
6
2
7
3
8
4
W±B
R±G
R±B
Connector A
IG
W±R (*1)
Y±R (*2)R±L (*1)
R±Y (*2)
*1: TMC Made
*2: TMUK Made
55±16
±
HEATER & AIR CONDITIONER COMBUSTION TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
2. DESCRIPTION OF DISPLAY AND BUTTONS
(a) AF: Current Value Malfunction (Blinking at current failure) Diag: DTC (Example: 064 Flame sensor break)
Memory Clear button: Deletion of faulty memory (Press both buttons together for longer than 2 se-
conds)
> Button: Scroll up of faulty memory (The past 5 codes can be stored.)\
< Button: Scroll down of faulty memory (The past 5 codes can be stored.\
)
3. FAULTY MEMORY
(a) The ECU is able to store up to 5 pieces of faulty memory. If it is full, the new data is written over F5.
4. WIRING DIAGRAM
http://vnx.su

38AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1AZ–FSE]
A5
F6
C6
A10
H2
H6
F11
F9
(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
E4
A6
A4
E5
F5
B1
H1
H5
E2
F7
F8
H9C2H10F16H7C1H8B3B2F13F12
H12A12A3C3A11H3F4H4H11A1A2E1A9F3F1
C5
(A/T)
(*1)
(*2)
(M/T)
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 2 Brake Booster Pressure Sensor
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 5 Counter Gear Speed Sensor
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
E 4 Electronic Driver Unit
E 5 Electronic Driver Unit
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH
F 3 Front Fog Light LH F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
F 16 Fuel Pressure Sensor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 7 Heated Oxygen Sensor (Bank 1 Sensor 1)
H 8 Heated Oxygen Sensor (Bank 1 Sensor 2)
H 9 Heated Oxygen Sensor (Bank 2 Sensor 1)
H 10 Heated Oxygen Sensor (Bank 2 Sensor 2)
H 11 Horn LH
H 12 Horn RH
http://vnx.su

40AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1AZ
–FE]
A5
F6
C6
A10
H2
H6
F11
F9(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
F5
A6
A4
B1
H1
E2
H5
F7
F8
A8C2H10A7C1H8B3F13F12
H12A12A3C3A11H3F4H4H11A1A2E1A9F3F1
C5
(A/T)
(*1)
(*2)
(M/T)
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 7 Air Fuel Ratio Sensor (Bank 1 Sensor 1)
A 8 Air Fuel Ratio Sensor (Bank 2 Sensor 1)
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 5 Counter Gear Speed Sensor
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH F 3 Front Fog Light LH
F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 8 Heated Oxygen Sensor (Bank 1 Sensor 2)
H 10 Heated Oxygen Sensor (Bank 2 Sensor 2)
H 11 Horn LH
H 12 Horn RH
http://vnx.su

42AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1ZZ–FE, 3ZZ–FE]
A5
F6
A12
A10
H2
H6
F11
F9
(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
F5
A6
A4
E2
B1
H1
H5
F7
F8
C2C6C1A11H7B3F13F12
A1H12A3C3H3F4H4H11E1A9F3F1
(*1)
(*2)
A 1 A/C Ambient Temp. Sensor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH
F 3 Front Fog Light LH
F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH
Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH
Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 7 Heated Oxygen Sensor (Bank 1 Sensor 1)
H 11 Horn LH
H 12 Horn RH
http://vnx.su

44AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1CD
–FTV]
E5
F6
A5
A10
E7
C6
E4
H2
H6
F11
F9(*1)
(*2) *1:w/ HID
*2:w/o HID
*3:Power Heater
(Hot Gas Type)
*4:Power Heater
(Electrical Type)
F10
F2
G2
A4
A6
F5
H1
H5
F7
F8
A12C1A11G1F18E3E2F16F17F15B3F13F12
H12C3A3A3
(*3) (*4)C4H3F4H4H11A1A2D1A9F3F1
B1
(*2) (*1)
F14
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 3 Compressor Assembly
C 4 Condenser Assembly
C 6 Crankshaft Position Sensor
D 1 Diesel Throttle Control Motor
E 2 EFI Water Temp. Sensor
E 3 EGR Valve Control Motor
E 4 Electronic Driver Unit
E 5 Electronic Driver Unit
E 7 Engine Oil Level Sensor
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH
F 3 Front Fog Light LH
F 4 Front Fog Light RH F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
F 14 Fuel Filter Warning SW
F 15 Fuel Heater
F 16 Fuel Pressure Sensor
F 17 Fuel Pump
F 18 Fuel Temp. Sensor
G 1 Glow Plug
G 2 Glow Plug Relay
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 11 Horn LH
H 12 Horn RH
http://vnx.su

58AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[RHD : 1AZ–FSE]
A5
F6
C6
A10
A11
H2
H6
F11
F9
(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
E4
A6
A4
E5
F5
B1
H1
E2
H5
F7
F8
F13B3C2B2H9F16H10C1H7H8
A1E6H12A12C3H3F4H4A2H11A3E1A9F3F1
C5
(A/T)
(*1)
(*2)
(M/T)
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 2 Brake Booster Pressure Sensor
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 5 Counter Gear Speed Sensor
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
E 4 Electronic Driver Unit
E 5 Electronic Driver Unit
E 6 Engine Hood Courtesy SW
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH F 3 Front Fog Light LH
F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH
Headlight RH (Low)
F 11 Front Washer Motor
F 13 Front Wiper Motor
F 16 Fuel Pressure Sensor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 7 Heated Oxygen Sensor (Bank 1 Sensor 1)
H 8 Heated Oxygen Sensor (Bank 1 Sensor 2)
H 9 Heated Oxygen Sensor (Bank 2 Sensor 1)
H 10 Heated Oxygen Sensor (Bank 2 Sensor 2)
H 11 Horn LH
H 12 Horn RH
http://vnx.su