Page 4745 of 5135
190JF−03
4
1
23
A34838
− STARTING & CHARGINGPRE−HEATING SYSTEM (1CD−FTV)(From September,
2003)19−13
AVENSIS Supplement (RM1045E)
INSPECTION
1. INSPECT GLOW PLUG RELAY ASSY
(a) Using an ohmmeter, measure the resistance between the
terminals.
Specified condition:
Tester ConnectionSpecified Condition
1−210 kor Higher
1−2
Below 1
(When battery voltage is applied to
terminals 3 and 4 )
If the result is not as specified, replace the glow plug relay.
Page 4746 of 5135

190V6−01
Z11580A80938A82936
Type A:
Type B:
BlueWhite
Red Green DarkClear or
light yellow
B00543
B00540
19−6
− STARTING & CHARGINGCHARGING SYSTEM (2AZ−FSE)
AVENSIS Supplement (RM1045E)
ON−VEHICLE INSPECTION
1. INSPECT BATTERY (EXCEPT MAINTENANCE−FREE
BATTERY)
(a) Check the battery electrolyte level.
(1) Check the electrolyte quantity of each cell.
If the electrolyte quantity is below the recommended amount,
add distilled water.
(b) Check the indicator as shown in the illustration.
HINT:
Indicator colorConditionType AType BCondition
GreenBlueOK
DarkWhiteCharging necessary
Clear or light yellowRedReplace
2. INSPECT BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Visually check the battery terminals.
(1) Check that the battery terminals are not loosened or corroded.
(b) Visually check the fusible link and fuses.
(1) Check that there is continuity of the fusible links, high−current fuses and regular fuses.
3. INSPECT V−RIBBED BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
SIf any defects are found, replace the v−ribbed belt.
SCracks on the rib side of the belt are considered ac-
ceptable.
If the belt has chunks missing from the ribs, it should
be replaced.
(b) Check that the belt fits properly in the ribbed grooves.
Confirm that the belt has not slipped out of the groove on the
bottom of the pulley by hand.
4. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that no abnormal noise is heard from the generator while the engine is running.
6. INSPECT CHARGE WARNING LIGHT CIRCUIT
Page 4747 of 5135

A88419
Disconnect Wire
from Terminal B
Generator Voltmeter
BatteryAmmeter
− STARTING & CHARGINGCHARGING SYSTEM (2AZ−FSE)
19−7
AVENSIS Supplement (RM1045E)
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine, then check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
7. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a tester is not available, connect a voltmeter to the
charging circuit as follows:
(1) Disconnect the wire from terminal B of the genera-
tor, then 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, then check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
8. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn the high beam headlights ON and turn the heater blower
switch to the ”HI” position.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
SIf the ammeter reading is less than the standard amperage, repair the generator.
SIf the battery is fully charged, the indication will sometimes be less than the standard amperage.
Page 4748 of 5135

170IZ−01
A57104
SST
A09582
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −11
AVENSIS Supplement (RM1045E)
OIL PUMP ASSY (1CD −FTV)(From September, 2003)
REPLACEMENT
1. DRAIN ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE ENGINE ROOM COVER SIDE
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER SUB −ASSY NO.1
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE ENGINE COVER SUB −ASSY NO.1 (See page 14 −90)
8. REMOVE INJECTOR DRIVER (See page 14 −108)
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
10. REMOVE GENERATOR V BELT (See Pub. No. RM1018E on page 14 −269)
11. SEPARATE POWER STEERING IDLE PULLEY BRACKET (See page 14 −138)
12. DISCONNECT ENGINE WIRE (See page 14 −138)
13. DISCONNECT VACUUM HOSE (See page 14 −108)
14. REMOVE ENGINE MOUNTING INSULATOR SUB −ASSY RH (See page 14 −138)
15. REMOVE CRANKSHAFT PULLEY (See page 14 −138)
SST 09213 −54015 (09213 −70020), 09330 −00021, 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05020, 09954 −05031)
16. REMOVE IDLER PULLEY SUB −ASSY (See page 14 −138)
17. REMOVE TIMING BELT NO.2 COVER (See page 14 −138)
18. REMOVE TIMING BELT NO.1 COVER (See page 14 −138)
19. REMOVE TIMING BELT GUIDE
20. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (See page 14 −138)
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14 −138)
22. REMOVE TIMING CHAIN COVER PLATE (See page 14 −138)
23. REMOVE TIMING BELT (See page 14 −138)
24. REMOVE TIMING BELT IDLER SUB −ASSY NO.2
25. REMOVE CRANKSHAFT TIMING PULLEY
(a) If the timing pulley cannot be removed by hand, use SST to remove the pulley.
SST 09950 −50013 (09951 −05010, 09952 −05010,
09953 −05010, 09953 −05020, 09954 −05021)
Page 4749 of 5135

B08016
O−ring
A85926
A56695
A79175
SST SST
17
−12
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
26. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
27. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
28. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
29. REMOVE TIMING BELT IDLER SUB −ASSY NO.1 (See page 16 −21)
30. REMOVE V −RIBBED BELT TENSIONER ASSY (See page 14 −108)
31. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt which secures the oil level gage guide to the cylinder block.
(b) Pull out the oil level gage guide together with the oil level gage from the No. 1 oil pan.
(c) Remove the O −ring from the oil level gage guide.
32. REMOVE ENGINE OIL LEVEL SENSOR
(a) Remove the 4 bolts and level sensor.
NOTICE:
Be careful not to drop the oil level sensor when removing.
33. REMOVE OIL PAN SUB −ASSY NO.2
(a) Remove the 16 bolts and 3 nuts.
(b) Insert the blade of SST between the No. 1 and No. 2 oil pans, then cut off the applied sealer and remove the No.
2 oil pan.
SST 09032 −00100
NOTICE:
Be careful not to damage the No. 1 and No. 2 oil pans.
Page 4750 of 5135
A56696
B08009
A56697
A56698
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −13
AVENSIS Supplement (RM1045E)
34. REMOVE OIL STRAINER SUB −ASSY
(a) Remove the 2 bolts and 2 nuts, then remove the oil strain- er and gasket.
35. REMOVE OIL PAN INSULATOR
(a) Remove the bolt and oil pan insulator.
36. REMOVE OIL PAN SUB −ASSY
(a) Remove the 19 bolts and 3 nuts.
(b) Using a screwdriver, remove the oil pan by prying be-
tween the cylinder block and No. 1 oil pan.
NOTICE:
Be careful not to damage the cylinder block and No. 1 oil
pan.
37. REMOVE CRANKSHAFT POSITION SENSOR (See page 14 −138)
Page 4751 of 5135

A56699
A56700
SST
B07987
New Gasket
Seal
Packing Seal Width
2to4mm
(0.08 to 0.16 in.)
B08024
17−14
− LUBRICATIONOIL PUMP ASSY (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
38. REMOVE OIL PUMP ASSY
(a) Remove the 9 bolts.
(b) Remove the oil pump by prying between the oil pump and
main bearing cap using a screwdriver.
(c) Remove the gasket.
39. INSTALL CRANKSHAFT SEAL
(a) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump edge.
SST 09316−60011 (09316−00011, 09316−00021)
40. INSTALL OIL PUMP ASSY
(a) Remove any old packing (FIPG). Be careful not to drop
any oil on the contact surfaces of the oil pump and cylin-
der block.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces and seal-
ing groove.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non−residue solvent, clean both the sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
Avoid applying an excessive amount to the surface.
(1) Install a nozzle of which opening is cut to 2 to 4 mm
(0.08 to 0.16 in.).
(2) The parts must be set within 3 minutes and must be
assembled within 15 minutes after applying seal
packing. Otherwise the material must be removed
and reapplied.
(3) Immediately remove the nozzle from the tube, then
reinstall the cap.
(c) Install a new gasket to the oil pump.
(d) Pour 0.5 cm
3(0.03 cu in.) or more of engine oil into the
bushing of the cylinder block.
(e) Apply engine oil to the cylinder block side which contacts
the oil pump driven rotor.
Page 4752 of 5135
A57099
A56702
−
LUBRICATION OIL PUMP ASSY (1CD −FTV)(From September, 2003)
17 −15
AVENSIS Supplement (RM1045E)
(f) Install the oil pump with the 9 bolts.
Torque: 31 N m (320 kgf cm, 23 ft lbf)
(g) Measure the oil pump rotating torque. (1) Check that the pump rotates smoothly without mak- ing a noise.
(2) Using a torque wrench, check the pump rotating torque.
Rotating torque: 3.0 N m (31 kgf cm, 27 in. lbf) or less
41. INSTALL CRANKSHAFT POSITION SENSOR (See page 14 −138)
42. INSTALL OIL PAN SUB −ASSY
(a) Remove any old packing (FIPG). Be careful not to drop any oil on the contact surfaces of the No. 1 oil pan, cylin-
der block, oil pump and rear oil seal retainer.
(1) Using a razor blade and gasket scraper, remove all
the old packing from the gasket surfaces.
(2) Thoroughly clean all components to remove all the
loose material.
(3) Using a non −residue solvent, clean both the sealing
surfaces.