2003 TOYOTA AVENSIS check engine light

B00543
B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter
Battery Ammeter
±
STARTING & CHARGING CHARGING SYSTEM (1CD±FTV)
19±27
AVENSIS REPAIR MANUAL (RM1018E)
5. 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.
(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.
6. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
7. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engin\
e is running.
8. 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. 9. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-ter and voltmeter as shown in the illustration.
(1) Disconnect to the wire from terminal B of the gener-ator and connect it to the negative (±) lead of the
ammeter.
(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: 13.2 to 14.8 V
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19±28
±
STARTING & CHARGING CHARGING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
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:
10. 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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190NQ±01
A81052
\b

A82936
Type A
Type B BlueWhite
Red
Green Dark
Clear or
light yellow
B00543
±
STARTING & CHARGING CHARGING 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 di\
stilled water if possible) andcheck the charging system.
2. CHECK BATTERY VOLTAGE
(a) If it has not been 20 minutes since you drove the vehicleor 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 20 C (68 F)
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 cordsetc.
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.
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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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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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3201G±07
BR2238
GOOD NO GOOD2nd 3rd
1st
BR2237
G24221
Ventilation No Ventilation
±
BRAKE BRAKE BOOSTER ASSY (LHD)
32±17
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (LHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight. (2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check. (1) Depress the brake pedal several times with the igni-tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve. (1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
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320GN±02
BR2238
GOOD NO GOOD2nd 3rd
1st
BR2237
G24221
Ventilation No Ventilation
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±21
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (RHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight. (2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check. (1) Depress the brake pedal several times with the igni-tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve. (1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
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D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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