TOYOTA AVENSIS 2002 Repair Manual

01±30±
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
The suspected circuits or parts for each problem symptom are shown in the t\
able below. Use this table to
troubleshoot the problem when a Normal code is displayed in the diagnostic trouble c\
ode chart but the prob-
lem is still occurring. Numbers in the table indicate the order in which\
the circuits or parts should be checked.
HINT:
When the problem is not detected by the diagnostic system even though the pr\
oblem symptom is present,
it may be that the problem is occurring outside the detection range of t\
he diagnostic system.
Symptom Suspected AreaSee page
1. With the ignition switch in ACC or ON position, the SRS warning
light sometimes lights up after approx. 6 seconds have elapsed.
2. SRS warning light is always lit up even when ignition switch is
in the LOCK position
1. With the ignition switch in the ACC or ON position, the SRS
warning light does not light up.
PROBLEM SYMPTOMS TABLE
1. DTC is not displayed. 05±187 05±183
Problem SymptomPage
Indicates the page where the flow chart for each circuit
is located.
Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.
Circuit or Part Name
Indicates the circuit or part which needs to be checked.
Proceed with troubleshooting of each circuit in the table below.
1. SRS warning light circuit
(Always lights up when ignition switch is in
LOCK position.)
1. SRS warning light circuit
(Does not light up when ignition switch is turned
to ACC or ON.)
1. Tc terminal circuit
05±180





3. DTC is displayed without Tc and CG terminal connection. 2. SRS warning light is always lit up at the time of DTC check
procedure.

SFI
SFISFI
SFISFI
SFI
D25842

Circuit Description
The major role and, operation of the circuit
and its component parts are explained.

Diagnostic Trouble Code No. and Detection Item

Indicates the diagnostic trouble codes, diagnostic
trouble code settings and suspect areas for a
problem.
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
Inspection Procedures
Use the inspection procedures to determine
if the circuit is normal or abnormal. If it is ab-
normal, use it to determine whether the prob-
lem is located in the sensors, actuators, wire
harness or ECU.

Indicates the condition of the connector of the ECU
during the check.


Connections of tester are
indicated by (+), (±) after
terminals name.
Connector being checked
is connected.Connector being checked
is disconnected.
For inspection of connector
with body ground, there is
nothing about the body
ground written down.
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01±31
AVENSIS REPAIR MANUAL (RM1018E)
CIRCUIT INSPECTION
How to read and use each page is shown below.

010B2±13
N17080
Filler Cap
Float
Reservoir Tank

Grommet
Clip
Slotted Spring Pin
: Specified torque

Non±reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot

Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
± INTRODUCTIONHOW TO USE THIS MANUAL
01±1
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ºDiagnosisº (found in the ºDiagnosticsº section), the 2nd
pro-
cess of ºRemoving and Installing, Replacing, Disassembling, Installing and Checking, and Adjustingº,
but the 3rd process of ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the
item to be repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed under the title where necessary.
(b) Non±reusable parts, grease application area, precoated parts and tightening torque are specified in
the component drawings.
Example:

Illustration:
what to do and where
Component part No. Detailed text: how to perform task
Task heading: what to do
Set part No
D31009
01±2
± INTRODUCTIONHOW TO USE THIS MANUAL
AVENSIS REPAIR MANUAL (RM1018E)
(c) Tightening torque, grease application area, and non±reusable parts are described as important points
in the procedures.
NOTICE:
There are cases where such information can only be explained by using an illustration. In these
cases, all the information such as torque, oil, etc. are described in the illustration.
(d) Installing procedures are performed in the reverse order of the removal and only the important points
are described.
(e) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notices are placed.
(f) There may be a case where the illustrations of similar models are used. In that case, specific details
may be different from the actual vehicle.
(g) The procedures are presented in a step±by±step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task and gives other information such as specifica-
tions and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary and the text below provides detailed information. Important
specifications and warnings always are written in bold type to stand out from the rest of the text.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for quick reference.
6. TERMS DEFINITION
CAUTIONIndicates the possibility of injury to you or other people.
NOTICEIndicates the possibility of damage to the components being repaired.
HINTProvides additional information to help you to perform the repair efficiently.

± INTRODUCTIONHOW TO USE THIS MANUAL
01±3
AVENSIS REPAIR MANUAL (RM1018E)
7. SI UNIT
(a) The units given in this manual are primarily expressed according to the SI UNIT (International System
of Units), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)

010LE±01
D30402
D30403
A
BC D
E
FG H
01±4
± INTRODUCTIONIDENTIFICATION INFORMATION
AVENSIS REPAIR MANUAL (RM1018E)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
1. VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped in the en-
gine compartment, as shown in the illustration. This num-
ber has also been stamped on the manufacturer's plate.
2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL
NUMBER
(a) The engine serial number is stamped on the cylinder
block of the engine and the transmission serial number is
stamped on the housing as shown in the illustration.
A: 1CD±FTV
B: 1AZ±FE, 1AZ±FSE
C: 1ZZ±FE, 3ZZ±FE
D: C50, C250
E: U241E
F: E354, E357, U241E
G: U241E
H: U341E

010LF±01



 

D25016
± INTRODUCTIONREPAIR INSTRUCTION
01±5
AVENSIS REPAIR MANUAL (RM1018E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1Looks
Always wear a clean uniform.

Hat and safety shoes must be worn.
2Vehicle protection
Set a grill cover, fender cover, seat cover and floor mat before starting operation.
3Safe operation

When working with 2 or more persons, be sure to check the safety of one another.

When working with the engine running, pay attention to providing ventilation for exhaust fumes in the work-
shop.

When working with high±temperatures, rotating, moving or vibrating parts, be careful not to burn or injure
yourself.

When jacking up the vehicle, be sure to support the specified location with a safety stand.

When lifting up the vehicle, use safety equipment.
4Preparation of tools and
measuring gauge
Before starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations

Diagnose with a thorough understanding of the trouble condition and perform effective operation.

Before removing the parts, check the general condition of the assembly, and for deformation and damage.

When the structure is complicated, take a notes or make matchmarks as not to make mistakes that affect the
function of the parts.

Clean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts

Place the removed parts in the correct order to avoid mixing them up or making them dirty.

As for non±reusable parts such as gaskets, O±rings, and self±locking nuts, replace them with new ones
following the instructions in this manual.

Organize the parts that were replaced in a box and show them to the customer.

Z11554
Seal Lock Adhesive
BE1367
Medium Current Fuse and High Current
Fuse Equal Amperage Rating


V35002
IllustrationSymbol Part Name Abbreviation
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE FUSE
M±FUSE H±FUSE
01±6
±
INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to li\
ft and support thevehicle at the proper locations (See page 01±19).
(c) PRECOATED PARTS(1) Precoated parts such as bolts, nuts, etc., are
coated with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry the part with compressed air.
Then apply the specified seal lock adhesive to the
bolt, nut or threads.
NOTICE:
Check the torque with the lower limit value of the torque tol-
erance.
(4) Depending on the seal lock agent to be applied,there may be cases where it is necessary to leave
it for a specified time until it hardens.
(d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always u\
se a torque wrench.
(f) FUSES(1) When replacing fuses, be sure that a new fuse hasthe correct amperage rating. DO NOT exceed the
rating, or use one with a lower rating.

D25786
Shape (Example)Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
Protective Tape
Clip



Protective Tape
± INTRODUCTIONREPAIR INSTRUCTION
01±7
AVENSIS REPAIR MANUAL (RM1018E)
(g) CLIPS
(1) The removal and installation methods of typical clips used in body parts are shown in the table
below.
HINT:
If the clip is damaged during the operation, always replace it with a new clip.

V00012
Shape (Example)
Removal/Installation
Removal
Installation Removal Installation
D25063
CORRECT
WRONG
D25064
01±8
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(h) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1) To disconnect vacuum hoses, pull them by holding
the end, not the middle of the hose.
(2) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected.
(3) After completing the job, make a double check
whether the vacuum hoses are properly connected.
A label under the hood shows the proper layout.
(4) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step±down
adapter for adjustment. Once the hose has been
stretched, it may leak air.