Page 3505 of 5135

A77467
Intake Side Exhaust Side
Gray
Black
A77468
SST
A77455
SST
Wooden Blocks
A77469
Vinyl Tape
Valve Stem
A77456
SST
Wooden Blocks 14±50
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
28. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on new valve stem seals.
NOTICE:
Pay much attention assembling the oil seal for intake and
exhaust. Installing the wrong one may cause improper
installation.
HINT:
The intake valve oil seal is gray and the exhaust valve oil seal
is black.
(b) Using SST, push in the oil seal.
SST 09201±41020
29. INSTALL INTAKE VALVE
(a) Install the parts below to the cylinder head.
1Intake valve
2Spring
3Retainer
(b) Using SST and wooden blocks, compress and install 2
valve spring retainer locks.
SST 09202±70020 (09202±00010)
(c) Wrap the tip of a discarded valve with vinyl tape, place the
discarded valve tip on the installed valve. Using a plastic±
faced hammer, lightly tap the discarded valve head to en-
sure proper fitting of the installed valve.
NOTICE:
Be careful not to damage the valve stem tip.
30. INSTALL EXHAUST VALVE
(a) Install the parts below to the cylinder head.
1Exhaust valve
2Spring
3Retainer
(b) Using SST and wooden blocks, compress and install 2
valve spring retainer locks.
SST 09202±70020 (09202±00010)
Page 3506 of 5135
A77469
Vinyl Tape
Valve Stem
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±51
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(c) Wrap the tip of a discarded valve with vinyl tape, place the
discarded valve tip on the installed valve. Using a plastic±
faced hammer, lightly tap the discarded valve head to en-
sure proper fitting of the installed valve.
NOTICE:
Be careful not to damage the valve stem tip.
31. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil on the valve lifter.
NOTICE:
Install the valve lifters to the original locations.
Page 3507 of 5135
190OK±01
A80108
B09748
B09749
B09750
± STARTING & CHARGINGGENERATOR ASSY
19±9
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
OVERHAUL
1. REMOVE GENERATOR REAR END COVER
(a) Remove the 2 terminal covers by turning them counter-
clockwise.
(b) Remove the screw and 2 nuts, and then detach the gener-
ator rear end cover.
2. REMOVE REGULATOR SUB±ASSY GENERATOR
W/BRUSH
(a) Remove the 3 screws and the regulator sub±assy gener-
ator w/ brush.
3. REMOVE STATOR SUB±ASSY GENERATOR
W/RECTIFIRE
(a) Remove the 4 bolts.
Page 3508 of 5135

B10446
B10014
B10015
B10452ContinuityOhmmeter
B10453
Ohmmeter
No Continuity 19±10
± STARTING & CHARGINGGENERATOR ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Using a screwdriver, pry out the stator sub±assy genera-
tor w/rectifire.
4. REMOVE BEARING SET GENERATOR
5. REMOVE PULLEY SET GENERATOR
(a) Clamp the swivel arm in a vise.
NOTICE:
Be careful not to damage the fan.
(b) Using an impact wrench or internal serration on rotor shaft
end together with a torque wrench,remove the nut and
spring washer, then detach the pulley.
6. REMOVE GENERATOR ROTOR ASSY
(a) Using a press, press out the generator rotor assy and
spacer ring.
7. INSPECT GENERATOR ROTOR ASSY
(a) Inspect the generator rotor assy for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the slip rings.
Standard resistance: 2.27 to 2.53 at 20C (68F)
If there is no continuity, replace the generator rotor assy.
(b) Inspect the generator rotor assy for ground.
(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and the generator rotor
assy.
If there is continuity, replace the generator rotor assy.
Page 3509 of 5135

B00896
B09842
Rectifier Terminal Positive (+) Terminal
No ContinuityOhmmeter
B09843
Negative (±) Terminal
No ContinuityOhmmeter Rectifier Terminal
B09844ContinuityOhmmeter Rectifier Terminal
± STARTING & CHARGINGGENERATOR ASSY
19±11
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(c) Inspect the slip rings.
(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor assy.
(2) Using vernier calipers, measure the slip ring diame-
ter.
Standard diameter: 15.3 to 15.5 mm (0.602 to 0.610 in.)
Minimum diameter: 14.3 mm (0.561 in.)
If the diameter is less than minimum, replace the generator ro-
tor assy.
8. INSPECT STATOR SUB±ASSY GENERATOR
W/RECTIFIRE
(a) Inspect the positive (+) rectifier.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
(3) Check that one shows continuity and the other
shows no continuity.
If result is not as specified, replace the stator sub±assy genera-
tor w/ rectifire.
(b) Inspect the negative (±) rectifier.
(1) Using an ohmmeter, connect one tester probe to
each negative (±) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
(3) Check that one shows continuity and the other
shows no continuity.
If result is not as specified replace the stator sub±assy genera-
tor w/ rectifire.
(c) Inspect the stator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the rectifier terminals.
If there is no continuity, replace the stator sub±assy generator
w/ rectifire.
Page 3510 of 5135

B09845
Length
B10019
SST
B10014
B09847
B09750
19±12
± STARTING & CHARGINGGENERATOR ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
9. INSPECT BRUSH
(a) Using vernier calipers, measure the brush length.
Standard exposed length:
11.0 to 13.6 mm (0.433 to 0.535 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the expose length is less than minimum, replace the voltage
regulator and the brush assembly.
10. INSTALL GENERATOR ROTOR ASSY
(a) Using SST and a press, press in the generator rotor assy.
SST 09285±76010
NOTICE:
Avoid misalignment during pressing
11. INSTALL PULLEY SET GENERATOR
(a) Clamp the rotor in a soft jaw vise.
(b) Install the pulley with the spring washer and nut.
Torque: 65 Nm (663 kgfcm, 48 ftlbf)
12. INSTALL BEARING SET GENERATOR
(a) Insert the fitting ring into in the position shown in the il-
lustration.
(b) Align the key of the fitting ring with the keyway of the stator
sub±assy generator w/ rectifire.
(c) Install the bearing.
13. INSTALL STATOR SUB±ASSY GENERATOR
W/RECTIFIRE
(a) Align the key of the drive end frame with the keyway of the
stator sub±assy generator w/ rectifire.
(b) Install the stator sub±assy generator w/ rectifire with the
4 bolts.
Torque: 3.5 Nm (36 kgfcm, 31 in.lbf)
Page 3511 of 5135
B09848
B10021
with Washer
without
Washer
B09748
Nut A
Screw
Nut B
A80108
± STARTING & CHARGINGGENERATOR ASSY
19±13
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
14. INSTALL REGULATOR SUB±ASSY GENERATOR
W/BRUSH
(a) Attach the brushes and the terminals to the rectifier end
frame of the regulator sub±assy generator w/ brush.
(b) Install the regulator sub±assy generator w/ brush with the
3 screws.
HINT:
Install the screw with the plate washer to the position shown in
the illustration.
Torque:
2.2 Nm (22 kgfcm, 19 in.lbf) for without washer
1.2 Nm (12 kgfcm, 11 in.lbf) for with washer
15. INSTALL GENERATOR REAR END COVER
(a) Install the generator rear end cover with the 2 nuts and the
screw.
Torque:
19.5 Nm (199 kgfcm, 14 ftlbf) for nut A
12 Nm (122 kgfcm, 9 ftlbf) for nut B
2.4 Nm (24 kgfcm, 21 in.lbf) for screw
(b) Install the 2 terminal covers by turning them clockwise.
Page 3512 of 5135

010BZ±02
01±6
± INTRODUCTIONTERMS FOR MANUAL TRANSAXLE REPAIR MANUAL
C250 M/T REPAIR MANUAL (RM1020E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Toyota equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric Pressure±
CACCharge Air CoolerInter cooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft positionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle Potion±
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 Communication 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 Control TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only
memoryElectrically 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 (DI)
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)
HO2SHeated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdol Air ControlIdol Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel±Shutoff±