1914

STARTING & CHARGING CHARGING SYSTEM (1AZFE)

CHARGING SYSTEM (1AZFE)

190NV01

PRECAUTION
1. 2. 3. 4. 5. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable is tightened on terminal B of the generator and the fuse box.

AVENSIS REPAIR MANUAL (RM1018E)

1915
STARTING & CHARGING CHARGING SYSTEM (1AZFE)
190NW01

ONVEHICLE INSPECTION
1. (a) CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. (1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.

2. (a)

(b) (c)
A81052

CHECK BATTERY VOLTAGE If it has not been 20 minutes since you drove the vehicle or 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. Turn off the ignition switch and the electrical systems. 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.

Type A Green Dark

Clear or light yellow

(d) Check the indicator as shown in the illustration. HINT:

Indicator color Type A Type B Blue White Red Green Condition OK Charging necessary Replace

Type B Blue White Red

Dark Clear or light yellow

A80938 Z11580

A82936

3. (a) (b)

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loosened or corroded. Check the fusible links, highcurrent fuses and regular fuses.

4. (a) HINT:
S S

INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. 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.

B00543

AVENSIS REPAIR MANUAL (RM1018E)

1916
STARTING & CHARGING CHARGING SYSTEM (1AZFE)

(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.

B00540

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 engine 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 warning light circuit. 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD Ammeter Disconnect Wire (a) According to the following procedure, connect an ammefrom Terminal B ter and voltmeter as shown in the illustration. (1) Disconnect the wire from terminal B of the generator Battery and connect it to the negative () lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terGenerator Voltmeter minal B of the generator (3) Connect the positive (+) lead of the voltmeter to terA75980 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: 12.9 to 14.9 V HINT: S If the voltmeter reading is more than standard voltage, replace the voltage regulator. S 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 HI position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more HINT: S If the ammeter reading is less than standard amperage, repair the generator. S If the battery is fully charged, the indication will sometimes be less than standard amperage.

AVENSIS REPAIR MANUAL (RM1018E)

1917
STARTING & CHARGING CHARGING SYSTEM (1AZFSE)

CHARGING SYSTEM (1AZFSE)

190NS01

PRECAUTION
1. 2. 3. 4. 5. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable is tightened on terminal B of the generator and the fuse box.

AVENSIS REPAIR MANUAL (RM1018E)

1918
STARTING & CHARGING CHARGING SYSTEM (1AZFSE)
190NT01

ONVEHICLE INSPECTION
1. (a) CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. (1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.

2. (a)

(b) (c)
A81052

CHECK BATTERY VOLTAGE If it has not been 20 minutes since you drove the vehicle or 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. Turn off the ignition switch and the electrical systems. 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.

Type A Green Dark

Clear or light yellow

(d) Check the indicator as shown in the illustration. HINT:

Indicator color Type A Type B Blue White Red Green Condition OK Charging necessary Replace

Type B Blue White Red

Dark Clear or light yellow

A80938 Z11580

A82936

3. (a) (b)

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loosened or corroded. Check the fusible links, highcurrent fuses and regular fuses.

4. (a) HINT:
S S

INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. 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.

B00543

AVENSIS REPAIR MANUAL (RM1018E)

1919
STARTING & CHARGING CHARGING SYSTEM (1AZFSE)

(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.

B00540

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 engine 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 warning light circuit.
Ammeter Disconnect Wire from Terminal B Battery Generator Voltmeter
A75980

8. (a)

(b)

INSPECT CHARGING CIRCUIT WITHOUT LOAD According to the following procedure, connect an ammeter and voltmeter as shown in the illustration. (1) Disconnect the wire from terminal B of the generator and connect it to the negative () lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative () lead of the voltmeter. 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: 12.9 to 14.9 V

HINT: If the voltmeter reading is more than standard voltage, replace the voltage regulator. S If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: INSPECT CHARGING CIRCUIT WITH LOAD Keep the engine speed at 2,000 rpm, turn on the high beam headlights and turn the heater blower switch to the HI position. Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the generator. If the battery is fully charged, the indication will sometimes be less than standard amperage.
S

9. (a) (b) HINT:

S S

AVENSIS REPAIR MANUAL (RM1018E)

1925
STARTING & CHARGING CHARGING SYSTEM (1CDFTV)

CHARGING SYSTEM (1CDFTV)

190NM01

PRECAUTION
1. 2. 3. 4. 5. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable is tightened on terminal B of the generator and the fuse box.

AVENSIS REPAIR MANUAL (RM1018E)

1926
STARTING & CHARGING CHARGING SYSTEM (1CDFTV)
190NN01

ONVEHICLE INSPECTION
1. (a) CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. (1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.

2. (a)

CHECK BATTERY SPECIFIC GRAVITY (MAINTENANCE TYPE BATTERY) Check the specific gravity of each cell. Standard specific gravity: 1.25 to 1.29 at 20_C (68_F)

HINT: If the specific gravity is less than specification, charge the battery.
A81051

3. (a)

(b) (c)
A81052

CHECK BATTERY VOLTAGE If it has not been 20 minutes since you drove the vehicle or 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. Turn off the ignition switch and the electrical systems. 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.

Type A Green Dark

Clear or light yellow

(d) HINT:

Check the indicator as shown in the illustration. (Non maintenance type battery)
Indicator color

Type B Blue White Red

Type A Green Dark Clear or light yellow

Type B Blue White Red

Condition Good Charging necessary Replace

A80938 Z11580

A82936

4. (a) (b)

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loosened or corroded. Check the fusible links, highcurrent fuses and regular fuses.

AVENSIS REPAIR MANUAL (RM1018E)

1927
STARTING & CHARGING CHARGING SYSTEM (1CDFTV)

5. (a) HINT:
S S

INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. 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.

B00543

(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.

B00540

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 engine 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 warning light circuit.
Ammeter Disconnect Wire from Terminal B Battery Generator Voltmeter
A75980

9. (a)

(b)

INSPECT CHARGING CIRCUIT WITHOUT LOAD According to the following procedure, connect an ammeter and voltmeter as shown in the illustration. (1) Disconnect to the wire from terminal B of the generator and connect it to the negative () lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative () lead of the voltmeter. 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

AVENSIS REPAIR MANUAL (RM1018E)

1928
STARTING & CHARGING CHARGING SYSTEM (1CDFTV)

HINT: If the voltmeter reading is more than standard voltage, replace the voltage regulator. S If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: INSPECT CHARGING CIRCUIT WITH LOAD Keep the engine speed at 2,000 rpm, turn on the high beam headlights and turn the heater blower switch to the HI position. Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the generator. If the battery is fully charged, the indication will sometimes be less than standard amperage.
S

10. (a) (b) HINT:

S S

AVENSIS REPAIR MANUAL (RM1018E)

194
STARTING & CHARGING CHARGING SYSTEM (1ZZFE/3ZZFE)

CHARGING SYSTEM (1ZZFE/3ZZFE)

190NP01

PRECAUTION
1. 2. 3. 4. 5. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. Check that the charging cable is tightened on terminal B of the generator and the fuse box.

AVENSIS REPAIR MANUAL (RM1018E)

195
STARTING & CHARGING CHARGING SYSTEM (1ZZFE/3ZZFE)
190NQ01

ONVEHICLE INSPECTION
1. (a) CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. (1) If the electrolyte is under the low level, replace the battery (or add distilled water if possible) and check the charging system.

2. (a)

(b) (c)
A81052

CHECK BATTERY VOLTAGE If it has not been 20 minutes since you drove the vehicle or 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. Turn off the ignition switch and the electrical systems. 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.

Type A Green Dark

Clear or light yellow

(d) Check the indicator as shown in the illustration. HINT:

Indicator color Type A Type B Blue White Red Green Condition OK Charging necessary Replace

Type B Blue White Red

Dark Clear or light yellow

A80938 Z11580

A82936

3. (a) (b)

CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loosened or corroded. Check the fusible links, highcurrent fuses and regular fuses.

4. (a) HINT:
S S

INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. 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.

B00543

AVENSIS REPAIR MANUAL (RM1018E)

196
STARTING & CHARGING CHARGING SYSTEM (1ZZFE/3ZZFE)

(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.

B00540

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 engine 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 warning light circuit.
Ammeter Disconnect Wire from Terminal B Battery Generator Voltmeter
A75980

8. (a)

(b)

INSPECT CHARGING CIRCUIT WITHOUT LOAD According to the following procedure, connect an ammeter and voltmeter as shown in the illustration. (1) Disconnect the wire from terminal B of the generator and connect it to the negative () lead of the ammeter. (2) Connect the positive (+) lead of the ammeter to terminal B of the generator (3) Connect the positive (+) lead of the voltmeter to terminal B of the generator. (4) Ground the negative () lead of the voltmeter. 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: 12.9 to 14.9 V

HINT: If the voltmeter reading is more than standard voltage, replace the voltage regulator. S If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: INSPECT CHARGING CIRCUIT WITH LOAD Keep the engine speed at 2,000 rpm, turn on the high beam headlights and turn the heater blower switch to the HI position. Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the generator. If the battery is fully charged, the indication will sometimes be less than standard amperage.
S

9. (a) (b) HINT:

S S

AVENSIS REPAIR MANUAL (RM1018E)

1920
STARTING & CHARGING GENERATOR ASSY (1AZFE/1AZFSE)

GENERATOR ASSY (1AZFE/1AZFSE)

190NK01

REPLACEMENT
1. (a) REMOVE ENGINE UNDER COVER LH Remove the 6 screws and 5 clips, and then remove the engine under cover.

A78515

2. (a) 3. 4. 5.
A78516

REMOVE ENGINE UNDER COVER RH Remove the 6 screws and the 3 clips, and then remove the engine under cover. REMOVE RADIATOR SUPPORT OPENING COVER (See page 1026) REMOVE ENGINE ROOM COVER SIDE (See page 1026) REMOVE FAN AND GENERATOR V BELT SST 0924963010 1AZFE: 14105 1AZFSE: 14185

HINT:
S S

(b)

(a)

6. (a) (b)

(b) (a)

REMOVE GENERATOR ASSY Disconnect the 2 heated oxygen sensor connectors. (1AZFE (Unleaded Gasoline) or 1AZFSE) Remove the 2 connector clamps of the heated oxygen sensor and the wire harness clamp. (1AZFE (Unleaded Gasoline) or 1AZFSE)

(b)
A77903

Terminal Cap (d) (e) (f)

(c) (d) (e) (f)

Remove the terminal cap. Remove the nut and disconnect the generator wire. Disconnect the generator connector. Remove the 2 wire harness clamps.

(f)
A77904

AVENSIS REPAIR MANUAL (RM1018E)

1921
STARTING & CHARGING GENERATOR ASSY (1AZFE/1AZFSE)

(g)

Remove the 2 bolts, and then remove the generator.

A77905

(h)

Remove the bolt, and then remove the wire harness clamp bracket.

A77906

7. (a) (b)
A

A77905

(c) (d) (e) (f) (g)

(h) 8. HINT:
S S

INSTALL GENERATOR ASSY Install the wire harness clamp bracket wire the bolt. Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf) Install the generator the 2 bolts. Torque: 52 NVm (530 kgfVcm, 38 ftVlbf) for bolt A 21 NVm (214 kgfVcm, 16 ftVlbf) for bolt B Install the 2 wire harness clamps. Connect the generator connector. Install the generator wire with the nut. Torque: 9.8 NVm (100 kgfVcm, 7 ftVlbf) Install the terminal cap. Install the 2 connector clamps of the heated oxygen sensor and the wire harness clamp. (1AZFE (Unleaded Gasoline) or 1AZFSE) Connect the 2 heated oxygen sensor connectors. (1AZFE (Unleaded Gasoline) or 1AZFSE)

INSTALL FAN AND GENERATOR V BELT SST 0924963010 1AZFE: 14105 1AZFSE: 14185 INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER INSTALL ENGINE UNDER COVER RH INSTALL ENGINE UNDER COVER LH

9. 10. 11. 12.

AVENSIS REPAIR MANUAL (RM1018E)

1929
STARTING & CHARGING GENERATOR ASSY (1CDFTV)

GENERATOR ASSY (1CDFTV)

190O101

REPLACEMENT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. REMOVE FRONT WHEEL RH REMOVE RADIATOR SUPPORT OPENING COVER REMOVE ENGINE ROOM COVER SIDE REMOVE ENGINE UNDER COVER SUBASSY NO.1 REMOVE ENGINE UNDER COVER RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14269) REMOVE GENERATOR V BELT (See page 14269) REMOVE FLOOR PANEL BRACE FRONT (See page 1510) REMOVE EXHAUST PIPE ASSY FRONT (See page 1510) REMOVE EXHAUST PIPE ASSY (W/ COLD AREA) (See page 1311) 11. (a) (b) (c) (d) REMOVE GENERATOR ASSY Remove the bolt and disconnect the wire harness. Remove the cap and nut, disconnect the generator wire. Disconnect the generator connector. Remove the 2 bolts and the generator.

A79176

12.

13. 14. 15. 16. 17. 18.

INSTALL GENERATOR ASSY Torque: 31 NVm (320 kgfVcm, 23 ftVlbf) for M8 47 NVm (475 kgfVcm, 34 ftVlbf) for M10 9.8 NVm (100 kgfVcm, 7 ftVlbf) for Generator wire 5.0 NVm (51 kgfVcm, 44 ftVlbf) for Wire harness INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) (See page 1311) INSTALL EXHAUST PIPE ASSY FRONT (See page 1510) INSTALL FLOOR PANEL BRACE FRONT (See page 1510) ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14286) INSTALL FRONT WHEEL RH Torque: 103 NVm (1,050 kgfVcm, 76 ftVlbf) CHECK FOR EXHAUST GAS LEAKS

AVENSIS REPAIR MANUAL (RM1018E)

197
STARTING & CHARGING GENERATOR ASSY (1ZZFE/3ZZFE)

GENERATOR ASSY (1ZZFE/3ZZFE)

190NI01

REPLACEMENT
1. 2. 3. 4. REMOVE REMOVE REMOVE REMOVE ENGINE UNDER COVER SUBASSY NO.1 (See page 1017) RADIATOR SUPPORT OPENING COVER (See page 109) ENGINE ROOM COVER SIDE (See page 109) FAN AND GENERATOR V BELT (See page 145)

(c)

(a) Terminal Cap No. 2 (e) (d)

5. (a) (b) (c) (d) (e)

REMOVE GENERATOR ASSY Disconnect the generator connector. Remove the terminal cap No. 2. Remove the nut and disconnect the generator wire. Disconnect the A/C connector. (w/ Air Conditioning) Remove the wire harness clamp. (w/ Air Conditioning)

A78487

(f)

Remove the 2 bolts, and then remove the generator.

A78488

7. 8. 9. 10.

INSTALL GENERATOR ASSY Install the generator with the 2 bolts. Torque: 25 NVm (255 kgfVcm, 18 ftVlbf) for bolt A 54 NVm (551 kgfVcm, 40 ftVlbf) for bolt B (b) Install the wire harness clamp. (w/ Air Conditioning) (c) Connect the A/C connector. (w/ Air Conditioning) B (d) Install the generator wire with the nut. A78488 Torque: 9.8 NVm (100 kgfVcm, 7 ftVlbf) (e) Install the terminal cap No. 2. (f) Connect the generator connector. INSTALL FAN AND GENERATOR V BELT (See page 145) INSTALL ENGINE ROOM COVER SIDE INSTALL RADIATOR SUPPORT OPENING COVER INSTALL ENGINE UNDER COVER SUBASSY NO.1
A

6. (a)

AVENSIS REPAIR MANUAL (RM1018E)

1933
STARTING & CHARGING GLOW PLUG ASSY (1CDFTV)

GLOW PLUG ASSY (1CDFTV)

190O201

REPLACEMENT
1. (a) REMOVE ENGINE COVER NO.1 Remove the 5 nuts and the engine cover.

2. (a) (b) (c)

REMOVE GLOW PLUG ASSY Remove the 5 grommets. Remove the 5 nuts and the glow plug connector. Remove the 4 glow plugs.

A79177

3.

4.

INSTALL GLOW PLUG ASSY Torque: 12.3 NVm (125 kgfVcm, 9 ftVlbf) for glow plug 2.2 NVm (22 kgfVcm, 19 in.Vlbf) for nut INSTALL ENGINE COVER NO.1 Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)

AVENSIS REPAIR MANUAL (RM1018E)

1930
STARTING & CHARGING PREHEATING SYSTEM (1CDFTV)

PREHEATING SYSTEM (1CDFTV)

190JE02

ONVEHICLE INSPECTION
NOTICE: Turn the ignition switch OFF for 60 seconds before performing the following inspections.

(sec.) 10 3 1 0 20 4

Light Lightning Time

1. (a)

INSPECT LIGHTING DURATION OF GLOW INDICATOR LIGHT Turn the ignition switch ON, and measure the lighting duration. Light lighting duration: Refer to the chart graph

0 28 32 82.4 Water Temperature

(_C) (_F)
A82619

Preheating Time (sec)

2. (a)

INSPECT PREHEATING Turn the ignition switch ON, measure how long it takes to the battery voltage is applied to the glow plugs. SST 0908200030, 0908300150 PreHeating time:
Engine coolant temperature 40 _C or more PreHeating time 1 sec Refer to the chart graph (15 sec at the longest)

Battery Voltage [V]

40 _C or less
A72562

(b)

Turn the ignition switch STA, check that the battery voltage applied to the glow plugs. SST 0908200030, 0908300150 (c) While cranking the engine, measure how long it takes to the battery voltage is applied to the glow plugs. SST 0908200030, 0908300150 PreHeating time:
Engine coolant temperature 40 _C or more 40 _C or less PreHeating time 1 sec Refer to the chart graph (15 sec at the longest)

(sec.)

After Glow Time

3. (a)

INSPECT AFTER GLOW TIME 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

1 0

20 68

40 104

(_C) (_F)
A80155

Water Temperature
AVENSIS REPAIR MANUAL (RM1018E)

1931
STARTING & CHARGING PREHEATING SYSTEM (1CDFTV)

Ohmmeter

Continuity

B08263

INSPECT GLOW PLUGS Using an ohmmeter, check that there is continuity between the glow plug terminal and ground. Standard resistance: Approx. 0.72 W at 20_C (68_F) NOTICE: S Be careful not to damage the glow plug pipes as it could cause an open circuit or shorten life of the glow plugs. S Avoid getting oil and gasoline on the glow plug when cleaning. S Wipe up any oil on the terminal and Bakelite washer with a dry cloth if they are stained with oil during inspection. S Be careful not to apply more than 11 V to the glow plug as it could cause an open circuit.

4. (a)

AVENSIS REPAIR MANUAL (RM1018E)

1932
STARTING & CHARGING PREHEATING SYSTEM (1CDFTV)
190JF02

INSPECTION

1. (a)

INSPECT GLOW PLUG RELAY ASSY Using an ohmmeter, check for continuity between each terminal. Specified condition:
No continuity 12 Continuity (Apply battery voltage terminals 3 and 4)

A34838

AVENSIS REPAIR MANUAL (RM1018E)

1912
STARTING & CHARGING STARTER ASSY (1AZFE/1AZFSE)

STARTER ASSY (1AZFE/1AZFSE)

190NJ01

REPLACEMENT
1. 2. 3. 4. REMOVE REMOVE REMOVE REMOVE RADIATOR SUPPORT OPENING COVER (See page 1026) BATTERY CLAMP SUBASSY BATTERY BATTERY TRAY

5. (a)

REMOVE BATTERY CARRIER Remove the 4 bolts, and then remove the battery carrier.

A77898

(a)

Terminal Cap Cover (c) (a) (d)

6. (a) (b) (c) (d)

REMOVE STARTER ASSY Remove the 3 wire harness clamps. Open the terminal cap cover. Remove the nut and disconnect the starter wire. Disconnect the starter connector.

(a)

A77899

(e)

Remove the 2 bolts, and then remove the starter.

A77900

(f)

Remove the bolt, and then remove the wire harness clamp bracket.

A77901

AVENSIS REPAIR MANUAL (RM1018E)

1913
STARTING & CHARGING STARTER ASSY (1AZFE/1AZFSE)

7. (a) (b) (c) (d) (e) (f) 8. 9. 10. 11.

12.

INSTALL STARTER ASSY Install the wire harness clamp bracket with the bolt. Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf) Install the starter with the 2 bolts. Torque: 37 NVm (380 kgfVcm, 28 ftVlbf) Connect the starter connector. Connect the starter wire with the nut. Torque: 9.8 NVm (100 kgfVcm, 7 ftVlbf) Close the terminal cap cover. Install the 3 wire harness clamps. INSTALL BATTERY CARRIER Torque: 13 NVm (131 kgfVcm, 9 ftVlbf) INSTALL BATTERY TRAY INSTALL BATTERY INSTALL BATTERY CLAMP SUBASSY Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) for bolt 3.6 NVm (36 kgfVcm, 31 in.Vlbf) for nut 5.4 NVm (55 kgfVcm, 48 in.Vlbf) for terminal INSTALL RADIATOR SUPPORT OPENING COVER

AVENSIS REPAIR MANUAL (RM1018E)

1924
STARTING & CHARGING STARTER ASSY (1CDFTV)

STARTER ASSY (1CDFTV)

190O001

REPLACEMENT
1. 2. 3. 4. 5. 6. (a) (b) (c) 7. DRAIN ENGINE COOLANT (See page 1644) REMOVE RADIATOR SUPPORT OPENING COVER REMOVE RADIATOR RESERVE TANK ASSY (See page 1650) REMOVE AIR CLEANER ASSY (See page 14286) REMOVE BATTERY REMOVE STARTER ASSY Remove the nut and disconnect terminal 30. Disconnect the starter connector. Remove the 2 bolts and the starter. INSTALL STARTER ASSY Torque: 37 NVm (377 kgfVcm, 27 ftVlbf) for bolt 9.8 NVm (100 kgfVcm, 7.2 ftVlbf) for terminal 30 INSTALL AIR CLEANER ASSY (See page 14286) INSTALL RADIATOR RESERVE TANK ASSY (See page 1650) ADD ENGINE COOLANT (See page 1644) CHECK FOR ENGINE COOLANT LEAKS (See page 1644)

8. 9. 10. 11.

AVENSIS REPAIR MANUAL (RM1018E)

193
STARTING & CHARGING STARTER ASSY (1ZZFE/3ZZFE)

STARTER ASSY (1ZZFE/3ZZFE)

190NH01

REPLACEMENT
1. REMOVE ENGINE UNDER COVER SUBASSY NO.1 (See page 1017)

Terminal Cap Cover (b) (a)

2. (a) (b) (c)

REMOVE STARTER ASSY Disconnect the starter connector. Open the terminal cap cover. Remove the nut and disconnect the starter wire.

A78485

(d)

Remove the 2 bolts, and then remove the starter.

A78486

3.

4.

INSTALL STARTER ASSY Torque: 37 NVm (378 kgfVcm, 28 ftVlbf) for bolt 9.8 NVm (100 kgfVcm, 7 ftVlbf) for nut INSTALL ENGINE UNDER COVER SUBASSY NO.1

AVENSIS REPAIR MANUAL (RM1018E)

198
STARTING & CHARGING STARTING SYSTEM (1AZFE)

STARTING SYSTEM (1AZFE)

190NU01

INSPECTION
1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do pullin test (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear is extended. If the clutch pinion gear is not extended, replace the magnetic switch.

Terminal 50

Terminal C
A78629

Do holdin test (1) Disconnect the negative () lead from terminal C with the above condition (a) is being maintained. Check that the pinion gear remains extended. If the clutch pinion gear returns, replace the magnetic switch.

(b)

Disconnect Disconnect

A78630

(c)

Inspect clutch pinion gear return (1) Disconnect the negative () lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch.

A78631

AVENSIS REPAIR MANUAL (RM1018E)

199
STARTING & CHARGING STARTING SYSTEM (1AZFE)

Terminal 30

(d)

Terminal 50 Ammeter

A78632

Do noload performance test (1) Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 NVm (60 kgfVcm, 52 inVlbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 85 A or less at 11.5 V

2. (a)

INSPECT STARTER RELAY ASSY Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal. Specified condition:
Terminal No. 12 35 Specified condition Continuity No continuity Continuity (Apply battery voltage terminals 1 and 2)

B16200

AVENSIS REPAIR MANUAL (RM1018E)

1910
STARTING & CHARGING STARTING SYSTEM (1AZFSE)

STARTING SYSTEM (1AZFSE)

190NR01

INSPECTION
1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do pullin test (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear is extended. If the clutch pinion gear is not extended, replace the magnetic switch.

Terminal 50

Terminal C
A78629

Do holdin test (1) Disconnect the negative () lead from terminal C with the above condition (a) is being maintained. Check that the pinion gear remains extended. If the clutch pinion gear returns, replace the magnetic switch.

(b)

Disconnect Disconnect

A78630

(c)

Inspect clutch pinion gear return (1) Disconnect the negative () lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch.

A78631

AVENSIS REPAIR MANUAL (RM1018E)

1911
STARTING & CHARGING STARTING SYSTEM (1AZFSE)

Terminal 30

(d)

Terminal 50 Ammeter A78632

Do noload performance test (1) Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 NVm (60 kgfVcm, 52 inVlbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 1.3kw 85 A or less at 11.5 V 1.6kw 75 A or less at 11.5 V

2. (a)

INSPECT STARTER RELAY ASSY Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal. Specified condition:
Terminal No. 12 35 Specified condition Continuity No continuity Continuity (Applying battery voltage terminals 1 and 2)

B16200

AVENSIS REPAIR MANUAL (RM1018E)

1922
STARTING & CHARGING STARTING SYSTEM (1CDFTV)

STARTING SYSTEM (1CDFTV)

190NL01

INSPECTION
1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do pullin test (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear is extended. If the clutch pinion gear is not extended, replace the magnetic switch.

Terminal 50

Terminal C
A78633

Do holdin test (1) Disconnect the negative () lead from the terminal C with the above condition (a) is being maintained. Check that the pinion gear remains extended. If the clutch pinion gear returns, replace the magnetic switch.

(b)

Disconnect

A78634

(c)
Disconnect

Inspect clutch pinion gear return (1) Disconnect the negative () lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch.

A78635

AVENSIS REPAIR MANUAL (RM1018E)

1923
STARTING & CHARGING STARTING SYSTEM (1CDFTV)

Terminal 30 Terminal 50

(d)

Ammeter

A78637

Do noload performance test (1) Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 NVm (60 kgfVcm, 52 inVlbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 190 A or less at 11.5 V

2. (a)

INSPECT STARTER RELAY ASSY Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal. Specified condition:
Terminal No. 12 35 Specified condition Continuity No continuity Continuity (Apply battery voltage terminals 1 and 2)

B16200

AVENSIS REPAIR MANUAL (RM1018E)

191
STARTING & CHARGING STARTING SYSTEM (1ZZFE/3ZZFE)

STARTING SYSTEM (1ZZFE/3ZZFE)

190NO01

INSPECTION
1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do pullin test (1) Disconnect the field coil lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear is extended. If the clutch pinion gear is not extended, replace the magnetic switch.

Terminal C Terminal 50
A82615

Do holdin test (1) Disconnect the negative () lead from terminal C with the above condition (a) is being maintained. Check that the pinion gear remains extended. If the clutch pinion gear returns, replace the magnetic switch.

(b)

Terminal C Terminal 50
A82616

(c)

Inspect clutch pinion gear return (1) Disconnect the negative () lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch.

Terminal C Terminal 50
A82617

AVENSIS REPAIR MANUAL (RM1018E)

192
STARTING & CHARGING STARTING SYSTEM (1ZZFE/3ZZFE)

(d)

Terminal C Terminal 50

A82618

Do noload performance test (1) Connect the field coil lead wire to terminal C. Make sure that the lead is not grounded. Torque: 5.9 NVm (60 kgfVcm, 52 inVlbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 85 A or less at 11.5 V

2. (a)

INSPECT STARTER RELAY ASSY Continuity inspection. (1) Using an ohmmeter, check for continuity between each terminal. Specified condition:
Terminal No. 12 35 Specified condition Continuity No continuIty Continuity (Apply battery voltage terminals 1 and 2)

B16200

AVENSIS REPAIR MANUAL (RM1018E)