axle TOYOTA AVENSIS 2002 Repair Manual

670SC±03
67±16
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
REPLACEMENT
1 . DISCONNEC T B ATTE RY NEG ATIVE TERMINAL ( See page 60±1)
2 . REMOVE INSTRUMENT CLUSTER FINISH P ANEL GARNISH NO.2 ( See page 71±11 )
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6 )
4 . REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) ( See page 41±11 )
5 . REMOVE CONSOLE PANEL SUB±ASSY UPPER ( See page 71±11 )
6 . REMOVE RADIO RECEIVER ASSEMB LY W/BRACKET ( See page 67±5)
7 . REMOVE CONSOLE BOX ASSY RR ( See page 71±11 )
8 . REMOVE HE ATER T O REGISTER DUCT NO.2 ( See page 71±11 )
9 . REMOVE FRONT SE AT ASSY RH ( See page POWER SE AT 72± 11 , MANUAL SE AT 72±16 )
10 . REMOV E FRONT DOOR SCUFF PL ATE RH ( See page 76±36 )
1 1 . REMOVE REAR DOOR SCUFF PL ATE RH ( See page 76±36 )
12 . REMOVE COWL SIDE TRIM BOARD RH ( See page 76±36)
13 . REMOVE FRONT DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
14 . REMOVE REAR DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
15 . REMOVE REAR SE AT CUSHION ASSEMB LY ( See page 72±32 )
16 . REMOVE REAR SE ATBACK ASSY ( See page 40/60 FOLDING 72±27 , UNITED FIXED 72±32 )
17 . REMOVE ROOF SIDE GARNISH INNER RH ( See page 76±36)
18. REMOVE FLOOR CARPET ASSY FRONT

670SD±02
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (WAGON MODELS)
67±19
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (WAGON MODELS)
REPLACEMENT
1. DISCONNEC T B ATTE RY NEG ATIVE TERMINAL ( See page 60±1)
2 . REMOVE INSTRUMENT CLUSTER FINISH P ANEL GARNISH NO.2 ( See page 71±11 )
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6 )
4 . REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) ( See page 41±11 )
5 . REMOVE CONSOLE PANEL SUB±ASSY UPPER ( See page 71±11 )
6 . REMOVE RADIO RECEIVER ASSEMB LY W/BRACKET ( See page 67±5)
7 . REMOVE CONSOLE BOX ASSY RR ( See page 71±11 )
8 . REMOVE HE ATER T O REGISTER DUCT NO.2 ( See page 71±11 )
9 . REMOVE FRONT SE AT ASSY RH ( See page POWER SE AT 72± 11 , MANUAL SE AT 72±16 )
10 . REMOVE FRONT DOOR SCUFF PL ATE RH ( See page 76±36 )
1 1 . REMOVE REAR DOOR SCUFF PL ATE RH ( See page 76±36 )
12 . REMOVE COWL SIDE TRIM BOARD RH ( See page 76±36)
13 . REMOVE FRONT DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
14 . REMOVE REAR DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
15. REMOVE REAR SEAT CUSHION ASSEMBLY (See page 40/60 FOLDING FLIP±UP CUSHION72±21 , 40/60 FOLDING 72±27 )
16. REMOVE REAR SEATBACK ASSY
(See page 40/60 FOLDING FLIP±UP CUSHION72±21 , 40/60 FOLDING 72±27 )
17. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 40/60 FOLDING FLIP±UP CUSHION72±21 , 40/60 FOLDING 72±27 )
18. REMOVE TONNEAU COVER ASSY
19 . REMOVE BACK DOOR WE ATHERSTRIP ( See page 76±54 )
20 . REMOVE DECK BOARD SUB±ASSY ( See page 76±54)
21 . REMOVE DECK FLOOR BOX REAR ( See page 76±54)
22 . REMOVE DECK FLOOR BOX FRONT ( See page 76±54)
23 . REMOVE DECK FLOOR BOX RH ( See page 76±54)
24 . REMOVE REAR FLOOR FINISH PL ATE ( See page 76±54 )
25 . REMOVE DECK TRIM SIDE BOARD RH ( See page 76±54)
26 . REMOVE ROOF SIDE GARNISH INNER RH ( See page 76±54)
27. REMOVE FLOOR CARPET ASSY FRONT

670SG±02
67±24
±
AUDIO & VISUAL SYSTEM ANTENNA CORD SUB±ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
ANTENNA CORD SUB±ASSY NO.3
REPLACEMENT
1 . DISCONNEC T B ATTE RY NEG ATIVE TERMINAL ( See page 60±1)
2 . REMOVE INSTRUMENT CLUSTER FINISH P ANEL GARNISH NO.2 ( See page 71±11 )
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6 )
4 . REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) ( See page 41±11 )
5 . REMOVE CONSOLE PANEL SUB±ASSY UPPER ( See page 71±11 )
6 . REMOVE RADIO RECEIVER ASSEMB LY W/BRACKET ( See page 67±5)
7 . REMOVE CONSOLE BOX ASSY RR ( See page 71±11 )
8 . REMOVE HE ATER T O REGISTER DUCT NO.2 ( See page 71±11 )
9 . REMOVE FRONT DOOR SCUFF PL ATE RH ( See page 76±36 )
10 . REMOVE REAR DOOR SCUFF PL ATE RH ( See page 76±36 )
1 1 . REMOVE COWL SIDE TRIM BOARD RH ( See page 76±36)
12 . REMOVE FRONT DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
13 . REMOVE REAR DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
14. REMOVE REAR SEAT CUSHION ASSEMBLY (See page 40/60 FOLDING FLIP±UP CUSHION 72±21 , 40/60 FOLDING 72±27 )
15. REMOVE REAR SEATBACK ASSY (See page 40/60 FOLDING FLIP±UP CUSHION 72±21 , 40/60 FOLDING 72±27 )
16. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 40/60 FOLDING FLIP±UP CUSHION 72±21 , 40/60 FOLDING 72±27 )
17 . REMOVE P ACKAGE TR AY TRIM P ANEL ASSY ( See page 76±45 )
18 . REMOVE REAR FLOOR FINISH PL ATE ( See page 76±45 )
19 . REMOVE DECK TRIM SIDE P ANEL ASSY RH ( See page 76±45)
20 . REMOVE ROOF SIDE GARNISH INNER RH ( See page 76±45)
21 . REMOVE FRONT SE AT ASSY RH ( See page POWER SE AT 72± 11 , MANUAL SE AT 72±16 )
22. REMOVE FLOOR CARPET ASSY FRONT

670SK±01
I352072 Claws
I35208
67±32
±
AUDIO & VISUAL SYSTEM POWER POINT SOCKET ASSY
AVENSIS REPAIR MANUAL (RM1018E)
POWER POINT SOCKET ASSY
REPLACEMENT
1. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) (See page 41±11)
2.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
5.REMOVE CONSOLE REAR END PANEL (See page 71±11)
6. REMOVE POWER POINT SOCKET ASSY
(a) Disengage the 2 claws and push out the power pointsocket to the room side.
(b) Remove the power point socket cover from the rear consol panel.
7. INSTALL POWER POINT SOCKET ASSY
(a) Install the power point socket cover to the rear consol panel.
(b) Align the claw of power point socket with the one of the socket cover, and push in the power point socket.

320VU±01
F45162
Vacuum Hose
ClipBrake Vacuum
Check Valve
Check Valve
Grommet
Clevis Pin
Clip Wave Washer
13 (130, 9)
Engine Room Relay Block Way
Clutch Reservoir Tube M/T Transaxle:
Front Brake
Tube No.5
15 (155, 11) *1
29 (296, 21) *2
Brake Fluid Level
Switch Connector

Brake Booster Gasket
20 (204, 15)
20 (204, 15)
Brake Master
Cylinder Sub±assy

Brake Booster Assy
Brake Master
Cylinder clevis
15 (155, 11)
Fuel Filter Assy Diesel Engine Type: Heater Assy w/ Cold Area:
Air Cleaner Assembly
With Hose
Clutch Tube M/T Transaxle:Gasoline Engine Type:
15 (155, 11)
*1
w/ ABS:
*2
w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
5.4 (55, 48 in.
lbf)
Charcoal Canister
Assy
32±18
± BRAKEBRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

F42620
F40019
32±20
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Install the clevis pin and clip to the brake master cylinder clevis.
(c) Connect the vacuum hose to the brake booster assy.
16. CONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, connect the brake tube to the flexible hose.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
17. INSTALL FRONT WHEEL LH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18.INSTALL HEATER ASSY (W/ COLD AREA) (See page 55±100)
19.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
20. INSTALL CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
21.INSTALL FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
22. CONNECT ENGINE ROOM RELAY BLOCK
23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
24.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
25.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
26.BLEED BRAKE LINE (See page 32±4)
27.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
28.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
29.CHECK PEDAL FREE PLAY (See page 32±6)
30.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
31. CHECK FUEL LEAK
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
33. CHECK BRAKE FLUID LEAKAGE

F45161
Brake Master
Cylinder Sub±assy
Clutch Master Cylinder AssyM/T Transaxle: Vacuum Tank Diesel Engine Type:
Brake Fulid Level
Switch Connector Accelerator Control
Cable Support
20 (204, 15)
19 (194, 14)
Clutch Reservoir
Hose M/T Transaxle: Brake Booster Assy
Brake Booster Gasket
Brake Master Cylinder
ClevisClip Clevis Pin
13 (130, 9)
15 (155, 11) *1
29 (296, 21) *2
15 (155, 11)
N
m (kgf
cm, ft
lbf)
: Specified torque
5.4 (55, 48 in.
lbf)
8.3 (85, 73 in.
lbf)
Wave Washer
Check Valve Grommet
15 (155, 11)
5.4 (55, 48 in.
lbf)
*1 w/ ABS:
*2 w/ VSC:
32±24
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)

320W4±01
G24211
F42291
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±25
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
3.REMOVE CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
4. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
5. REMOVE ENGINE COVER NO.1
6.REMOVE IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
7.REMOVE CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
8.REMOVE TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)
9.REMOVE CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
10.REMOVE INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
11. REMOVE FRONT WHEEL RH
12. REMOVE BRAKE TUBE
(a) w/o VSC:Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100
(b) w/ VSC: Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100, 09023±38400

32±32
±
BRAKE BRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
26. INSTALL ENGINE COVER NO.1
27.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
28.INSTALL CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
29.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
30.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
31.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100, 09023±00100
(b) w/ VSC: SST 09023±00100, 09023±00100
32.BLEED BRAKE LINE (See page 32±4)
33.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
34.CHECK PEDAL FREE PLAY (See page 32±6)
35.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
36.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
37.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (M/T TRANSAXLE) (See page 42±2)
38.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
39. CHECK BRAKE FLUID LEAKAGE
40. CHECK CLUTCH FLUID LEAKAGE (M/T TRANSAXLE)

320W5±01
G24285
LHD Steering Position Type:
Charcoal Canister Assy
Brake Fluid Level
Switch Connector
Clutch Reservoir
Tube M/T Transaxle:Brake Booster Assy
Clip
Way
20 (204, 15)
15 (155, 11)
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Brake Master
Cylinder Sub±assy
20 (204, 15)
Engin Room Relay Block
RHD Steering Position Type:Air Cleaner Cap Sub±assy
Brake Fluid Level
Switch ConnectorBrake Master
Cylinder Sub±assy
Clip
Accelerator Control
Cable Support
20 (204, 15)
*1

w/ ABS:*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Clutch Reservoir
Tube M/T Transaxle:
Brake Booster Assy
5.4 (55, 48 in.
lbf)
Fuel Filter Assy Diesel Engin Type:
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS