TOYOTA AVENSIS 2003 Service Manual PDF

010LF±01






D25016
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INTRODUCTION REPAIR 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 ventila\
tion for exhaust fumes in the work-
shop.

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

When jacking up the vehicle, be sure to support the specified location w\
ith 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 perf\
orm 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 no\
t 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±lo\
cking 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 cust\
omer.
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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
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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.
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D25786
Shape (Example)Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
Protective Tape
Clip



Protective Tape
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INTRODUCTION REPAIR INSTRUCTION
01±7
AVENSIS REPAIR MANUAL (RM1018E)
(g) CLIPS
(1) The removal and installation methods of typical clips used in body parts ar\
e shown in the tablebelow.
HINT:
If the clip is damaged during the operation, always replace it with a new \
clip.
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V00012
Shape (Example)Removal/Installation
Removal Installation
Removal Installation
D25063
CORRECT
WRONG
D25064
01±8
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INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(h) REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect vacuum hoses, pull them by holdingthe 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.
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L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
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INTRODUCTIONREPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE (1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.
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D30401
Mark
01±10
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INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Even in the case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly and seat belt pretensioner should be in\
spected
(See pages 60±19, 60±19 and 61±9).
(4)Never use the SRS related parts from another vehicle. When replacing the part\
s, replace them with new parts.
(5)Before repairs, remove the airbag sensor if there is a possibility of sh\
ock during repairs.
(6)Never disassemble and repair the center airbag sensor assembly, side airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly,
curtain shield airbag assembly or seat belt pretensioner.
(7)If the center airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly have been dropped, or if the\
re are cracks,
dents or other defects in the case, bracket or connector, replace them with new ones.
(8)Do not directly expose the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly or the seat belt pretensioner
to hot air or flames.
(9)Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting electrical cir-
cuits.
(10)Information labels are attached to the SRS components. Follow the instru\
ctions on the notices.
(11)After work on the supplemental restraint system is completed, check the SRS w\
arning light (See page 05±1184)
(b)SPIRAL CABLE (in Combination Switch)(1)The steering wheel must be fitted correctly to thesteering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
troubles may occur. Refer to page 60±26 of this
manual concerning the correct installation of the
steering wheel.
(c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it sho\
uld be placed withthe top of the pad surface facing upward. Placing it with the pad surface facing downward may
lead to a serious accident if the airbag deploys for some reasons. Also, do \
not place anything
on top of the horn button.
(2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
(3) Grease should not be applied to the horn button assembly, and the pad should not be cleaned with any type of detergent.
(4) Store the horn button assembly where the ambient temperature remains below 93
C (200
F),
without high humidity and away from electrical noise.
(5) When using electric welding, disconnect the airbag connector (4 yellow pins\
) under the steering column near the combination switch connector before starting work.
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D25096
Example:CORRECTWRONG
Z13950
Example:
D27522
Example: CORRECT WRONG
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INTRODUCTIONREPAIR INSTRUCTION
01±11
AVENSIS REPAIR MANUAL (RM1018E)
(6)When disposing the vehicle or the horn button assembly alone, the airbag\
should be inflated us-
ing an SST before disposal (See page 60±19).
Perform the operation in a safe place away from electrical noise.
(d)INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (1)Always place a removed or new instrument panel passenger airbag assembly\
with the airbaginflation direction facing upward. Placing the airbag assembly with the airbag inflation direction
facing downward could cause a serious accident if the airbag deploys.
(2)Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
(3)Grease should not be applied to the instrument panel passenger airbag assembly\
and the airbag door should not be cleaned with detergents of any kind.
(4)Store the airbag assembly where the ambient temperature remains below 93
C (200
F), without
high humidity and away from electrical noise.
(5)When using electric welding, disconnect the airbag connector (4 yellow pins\
) installed on the as- sembly before starting work.
(6)When disposing of a vehicle or the airbag assembly unit, the airbag should be deployed using\
SST before disposal (See page 60±30).
Activate in a safe place away from electrical noise.
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Z13951
Example:
D26612
Example:CORRECT WRONG
B01546
Example:
01±12
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INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(e)FRONT SEAT AIRBAG ASSEMBLY (1)Always store a removed or new front seat airbag assembly with the airbag infla\
ting direction fac-
ing upward.
Placing the airbag assembly with the airbag inflation direction facing d\
ownward could cause a
serious accident if the airbag inflates.
(2)Never measure the resistance of the airbag squib (This may cause the ai\
rbag to inflate, which
is very dangerous.).
(3)Grease should not be applied to the front seat airbag assembly and the airbag d\
oor should not be cleaned with detergents of any kind.
(4)Store the airbag assembly where the ambient temperature remains below 93
C (200
F), without
high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the airbag connector (2 yello\
w pins) installed on the assembly before starting work.
(6)When disposing of a vehicle or the side airbag assembly alone, the airbag sh\
ould be inflated us- ing an SST before disposal (See page 60±47).
Perform the operation in a safe place away from electrical noise.
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D30399
Example:CORRECT WRONG
D30398
Example:
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INTRODUCTIONREPAIR INSTRUCTION
01±13
AVENSIS REPAIR MANUAL (RM1018E)
(f)INSTRUMENT PANEL LOWER AIRBAG ASSEMBLY
(1)Always store a removed or new instrument panel lower airbag assembly with the \
airbag inflatingdirection facing upward.
Placing the airbag assembly with the airbag inflation direction facing d\
ownward could cause a
serious accident if the airbag inflates.
(2)Never measure the resistance of the airbag squib (This may cause the ai\
rbag to inflate, which is very dangerous.).
(3)Grease should not be applied to the instrument panel lower airbag assembly and\
the airbag door should not be cleaned with detergents of any kind.
(4)Store the instrument panel lower airbag assembly where the ambient temperature remains be- low 93
C (200
F), without high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the airbag connector (2 yello\
w pins) installed on the
instrument panel lower airbag assembly before starting work.
(6)When disposing of a vehicle or the instrument panel lower airbag assembly alone, the airbag should be inflated using an SST before disposal (See page 60±55).
Perform the operation in a safe place away from electrical noise.
(g) CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keepit in a safe place.
NOTICE:
Protection bag is not re±useable.
CAUTION:
Never disassemble the curtain shield airbag assembly. (2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, whichis very dangerous).
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D26602
Example:CORRECT WRONG
Clear Plastic Bag
D26603
Example:
01±14
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INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind.
(4)Store the airbag assembly where the ambient temperature remains below 93
C (200
F), without
high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the airbag connector (4 yellow pins) from th\
e instru- ment panel before starting work.
(6)When disposing of a vehicle or the curtain shield airbag assembly alone, the airbag should be
deployed using SST before the disposal (See page 60±41). Perform operation in a safe place
away from electrical noise.
(h)SEAT BELT PRETENSIONER (1)Never measure the resistance of the seat belt pretensioner (This may cause t\
he seat belt preten-sioner to activate, which is very dangerous.).
(2)Never disassemble the seat belt pretensioner.
(3)Never install the seat belt pretensioner in another vehicle.
(4)Store the seat belt pretensioner where the ambient temperature remains b\
elow 80
C (176
F)
without high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the connector (2 yellow pins) before starting work.
(6)When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensi\
oner should
be activated before disposal (See page 61±9). Perform the operation in a safe place away from
electrical noise.
(7) The seat belt pretensioner is hot after being activation, so allow some \
time for it to cool down sufficiently before disposal. Never apply water to cool down the seat be\
lt pretensioner.
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