air filter TOYOTA AVENSIS 2003 Service Manual PDF

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
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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 Connector Brake 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:
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS
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320W6±01
G24218
G24217
F45393
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±13
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 ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
3. REMOVE AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
4. REMOVE CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
5. REMOVE FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
(a) Diesal engine type:
Remove the fuel filter assy with the 3 bolts.
6. REMOVE BRAKE MASTER CYLINDER SUB±ASSY(LHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle: Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Using SST, disconnect the 2 brake lines from the way. SST 09023±00100
(f) Remove the 2 nuts, and pull out the way and brake master cylinder sub±assy.
(g) Remove the O±ring from the brake master cylinder sub±
assy.
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G24225
32±16
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(c) w/o VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(d) w/ VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±38400
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
(e) M/T transaxle: Slide the clip and connect the clutch reservoir tube.
(f) Connect the brake fluid level switch connector.
12. INSTALL CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
13. INSTALL ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
14. INSTALL AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
15. INSTALL FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
16.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
17.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
18.BLEED BRAKE LINE (See page 32±4)
19.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
20.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
21. CHECK BRAKE FLUID LEAKAGE
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550YQ±01
I35277
Blower Assy
Air Duct No.2
Recirculation Damper Servo Sub±assy
Air FilterAir Filter Case
Blower w/ fan Motor Sub±assy
Manual A/C: Blower Resistor
Air Conditioning Wire No.1
Auto A/C:
Blower Motor Control
9.8 (100, 87 in.
lbf)
Cooler Wiring No.1Manual A/C:
N

m (kgf
cm, ft
lbf): Specified torque
55±64
±
HEATER & AIR CONDITIONER BLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
BLOWER ASSY
COMPONENTS
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I353162 Claws
I35318
I35319Clamp
I35320
55±66
±
HEATER & AIR CONDITIONER BLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE AIR FILTER CASE
(a) Release the 2 claw fittings and remove the air filter case.
6. REMOVE AIR FILTER 7. REMOVE RECIRCULATION DAMPER SERVOSUB±ASSY
(a) Remove the 2 screws and the recirculation damper servo sub±assy.
8. REMOVE AIR CONDITIONING WIRENO1 (MANUAL AIR CONDITIONING)
(a) Disconnect the connector.
(b) Release the clump and remove the air conditioning wire No.1.
9. REMOVE COOLER WIRING NO.1 (AUTO AIR CONDITIONING)
HINT:
Disconnection of the cooler wiring No.1 is the same as the air condition\
ing wire No.1. 10. REMOVE BLOWER RESISTOR (MANUAL AIRCONDITIONING)
(a) Remove the 2 screws and the blower resistor.
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I35321
I35322
I35317
I36813
I35314
±
HEATER & AIR CONDITIONER BLOWER ASSY
55±67
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE BLOWER MOTOR CONTROL (AUTO AIR
CONDITIONING)
(a) Remove the 2 screws and the blower motor control.
12. REMOVE BLOWER W/FAN MOTOR SUB±ASSY
(a) Remove the 3 screws and the blower w/ fun motor sub±
assy.
13. INSTALL AIR FILTER
(a) Install the air filter as shown in the illustration.
14. INSTALL BLOWER ASSY
(a) Install the blower assy with the claw fitting.
(b) Install the blower assy with the 2 bolts and the 2 screws. Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf) (Bolt)
(c) Install the 2 nuts.
(d) Connect the connectors.
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550YS±01
I35345Claw
I35346
I35347
I35348
55±100
±
HEATER & AIR CONDITIONER HEATER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
HEATER ASSY
REPLACEMENT
1.REMOVE AIR CLEANER ASSY (See page 11±82)
2.REMOVE FUEL FILTER ASSY (See page 11±82) 3. REMOVE AIR DUCT NO.3
(a) Release the claw fitting and remove the bolt and the en-gine room relay No.2 block.
(b) Remove the clip and the air duct No.3.
4. DISCONNECT HEATER INLET WATER HOSE
(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.
HINT:
Prepare a support plate and waste to catch the leaked coolant.
5. DISCONNECT HEATER WATER INLET HOSE A
(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose A.
HINT:
Prepare a support plate and waste to catch the leaked coolant.
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I35349
I35350
I35350
I35349
±
HEATER & AIR CONDITIONER HEATER ASSY
55±101
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE HEATER ASSY
(a) Using pliers, grip the claws of the clip and slide the clip to
disconnect the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
(b) Disconnect the connector.
(c) Remove the 2 bolts and the heater assy.
7. INSTALL HEATER ASSY
(a) Install the heater assy with the 2 bolts. Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
(b) Connect the connector.
(c) Install the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
8.INSTALL FUEL FILTER ASSY (See page 11±82)
9.INSTALL AIR CLEANER ASSY (See page 11±82)
10.ADD ENGINE COOLANT (See page 16±44)
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±37)
12.CHECK FUEL LEAK (See page 11±56)
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E65563
I22117
Condition: Air conditioning system periodically repeats proper and improper functi\
on.
±
HEATER & AIR CONDITIONER REFRIGERANT
55±33
AVENSIS REPAIR MANUAL (RM1018E)
(1) When the refrigerant volume is proper:
Gauge reading:
Low pressure side:
0.28 ± 0.4 MPa (2.8 ± 4.0 kgf/cm
2)
High pressure side:
1.3 ± 1.6 MPa (13 ± 16 kgf/cm
2)
(2) When there is moisture in the refrigeration system:
SymptomProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side cycles between nor-
mal and vacuum
Moisture in refrigeration system
freezes at refrigerant filter orifice,
causing a temporary stop of cycle.
However, when it melts, normal
state is restored
Drier is overly saturated

Moisture in refrigeration system
freezes at refrigerant filter orifice
and blocks circulation of refriger-
ant(1) Replace cooler drier
(2) Remove moisture in cycle by
repeatedly vacuuming
(3) Supply proper amount of new
refrigerant
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