TOYOTA AVENSIS 2003 Service Repair Manual

I35138
LHD:FUSE
1. ±
2. DEF I/ UP 7.5A
3. ST 7.5A
4. MIR HTR 7.5A
5. RAD No.2 15A 6. DOME 7.5A
7. ECU±B2 7.5A
8. PWR SEAT 30A
9. ±
10. P±RR P/W 20A 11. P±FR P/W 20A
12. D±RR P/W 20A
13. D±FR P/W 20A
14. ECU±B1 7.5A
15. FUEL OPN 10A
16. FR DIC 20A
RELAY
A. ST
B. FR FOG
C. P/POINT
D. FR DEICER A
B
13 14 15
9 34567
8
C
D
16
11 1 2
10
12
Fuse Block Assy
Drive Side Relay Block Assy
68±6
±
WIRING POWER SOURCE
AVENSIS REPAIR MANUAL (RM1018E)
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I35137
AB
CD
13 14 15
9 3 456 7
8 16
10 12 11
12
RHD:
Fuse Block Assy
FUSE
1. ±
2. DEF I/ UP 7.5A
3. ST 7.5A
4. MIR HTR 10A
5. RAD No.2 15A 6. DOME 7.5A
7. ECU±B2 7.5A
8. PWR SEAT 30A
9. ±
10. P±RR P/W 20A 11. D±FR P/W 20A
12. P±RR P/W 20A
13. P±FR P/W 20A
14. ECU±B1 7.5A
15. FUEL OPN 10A
16. FR DIC 20A
Passenger Side Relay Block Assy
RELAY
A. P/POINT
B. FR FOG
C. ST
D. FR DEICER
±
WIRING POWER SOURCE
68±7
AVENSIS REPAIR MANUAL (RM1018E)
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69067±02
B67410
±
COMMUNICATION SYSTEM HIGH PITCHED HORN ASSY
69±5
AVENSIS REPAIR MANUAL (RM1018E)
HIGH PITCHED HORN ASSY
REPLACEMENT
1. REMOVE HIGH PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL HIGH PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator supportupper, and then install the horn with the bolt.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the connector.
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69064±02
B67409
Low Pitched HornHORN Relay
High Pitched Horn
Engine Room R/B No. 2Engine Room R/B

HORN Fuse
±
COMMUNICATION SYSTEM HORN SYSTEM
69±1
AVENSIS REPAIR MANUAL (RM1018E)
HORN SYSTEM
LOCATION
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69065±02
69±2
±
COMMUNICATION SYSTEMHORN SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee Page
Horn does not sound
1. Horn button switch
2. High pitched horn
3. Low pitched horn
4. HORN fuse
5. HORN relay
6. Wire harness±
69±3
69±3
69±3 ±
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69066±02
B67416
B67417
B68374
21
5
3
±
COMMUNICATION SYSTEM HORN SYSTEM
69±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT LOW PITCHED HORN ASSY
(a) Check operation of the horn.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+) Terminal 1
Battery positive (±) Horn bodyHorn sounds
If the result is not as specified, replace the horn assy.
2. INSPECT HIGH PITCHED HORN ASSY
(a) Check operation of the horn.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+) Terminal 1
Battery positive (±) Horn bodyHorn sounds
If the result is not as specified, replace the horn assy.
3. INSPECT HORN RELAY ASSY
(a) Remove the HORN relay from the engine room R/B No.
2.
(b) Check the horn relay resistance.
Standard:
Tester ConnectionSpecified Condition
10 k
or higher
3 ± 5Below 1

(When battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay assy.
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69068±02
B67411
69±4
±
COMMUNICATION SYSTEM LOW PITCHED HORN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
LOW PITCHED HORN ASSY
REPLACEMENT
1. REMOVE LOW PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn. 2. INSTALL LOW PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator supportupper, and then install the horn with the bolt.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the connector.
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700T7±01
B67059
Back Door Side Garnish RHCenter Stop Lamp AssyBack Door Trim Board
Back Door Side Garnish LH
Back Door Trim
Panel Assy Upper
Wiper Arm Head Cap
Rear Wiper Arm Assy
Wiper Motor Assy

Back Door Glass
: Specified torque
N
m (kgf
cm, ft
lbf)

Non±reusable part
5.5 (56, 49 in.
lbf)5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
70±34
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GLASS (LIFTBACK MODELS)
COMPONENTS
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700T8±01
B68025
Piano Wire
Clip
B69235
Protective Tape
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
70±35
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1.REMOVE BACK DOOR TRIM BOARD ASSY (See page 75±40)
(a) Remove the back door trim panel assy upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE CENTER STOP LAMP ASSY (See page 65±26)
3.REMOVE REAR WIPER MOTOR ASSY (See page 66±17
)
(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to prevent the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around the glass.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
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BO4421
Adhesive
Adhesive
BO4420Body
B67821
Primer M
Primer M
AdhesiveCORRECT
WRONG
: Primer M
70±36
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
5. CLEAN BACK DOOR GLASS
(a) Clean the outer circumference of the glass with white gas- oline.
NOTICE:

Do not touch the glass surface after cleaning it.

Be careful not to damage the body.
6. INSTALL BACK DOOR GLASS
(a) Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on thecontact surface of the body to ensure the appropri-
ate surface shape.
HINT:
Leave as much adhesive on the body as possible.
(2) Clean the contact surface of the body with a pieceof shop rag saturated with cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
(b) Using a brush, coat the exposed part of the body on the
vehicle side with Primer M.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not coat the adhesive with Primer M.

Do not keep any of the opened Primer M for later use.
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