dimensions TOYOTA AVENSIS 2003 Service Repair Manual

MO
NEW MODEL OUTLINE


mm (in.)
2700 14801760
Front: 1505*
1, 1515*2
Rear: 1500*1, 1515*2
910 1025


270014801760
910 1025 Front: 1505*1, 1515*2
Rear: 1500*1, 1515*2


270015251760
910 1095 Front: 1505*1, 1515*2
Rear: 1500*1, 1515*2
*1: 16 in. or 17 in.Tire
*2: 15 in. Tire
MO-27
DIMENSIONS
4-Door Sedan
5-Door Liftback
5-Door Wagon
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D30400
Swing Arm Type Lift
Plate Type LiftCenter of Lift
: CENTER OF VEHICLE
GRAVITY (unloaded condition) Rubber Attachment
AttachmentBAL
Attachment Dimensions
85 mm (3.35 in.)
200 mm (7.87 in.)
100 mm (3.94 in.) 70 mm
(2.76 in.)
C
01±20
±
INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
4. NOTICE FOR USING SWING ARM TYPE LIFT
(a) Follow the instruction manual of the lift for a safe operation.
(b) Use a cradle with a rubber attachment, as shown in the illustration.
(c) Set in the vehicle so as to make its center of gravity as close as possible\
to the center of the lift. (ºLº becomes short.)
(d) Place the vehicle horizontally by adjusting the height of the cradle, and match th\
e groove of the cradle and the safety stand support location accurately.
(e) Be sure to lock the swing arm during the operation.
(f) Lift the vehicle up until the tires float, and shake the vehicle to make\
sure that the vehicle is stable.
5. NOTICE FOR USING PLATE TYPE LIFT
(a) Follow the instruction manual of the lift for a safe operation.
(b) Use a plate lift attachment.
(c) Be sure to set the vehicle to the specified position.
Right and left set position
Place the vehicle over the center of the lift.
Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (\
A and C).

Align the attachment upper end (B) with the rocker flange front side n\
otch.
(d) Lift the vehicle up until the tires float a bit, and shake the vehicle t\
o make sure that the vehicle is stable.
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H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42761
Width
Inner
Diam.
H42792
SST(s)
60±44
±
SUPPLEMENTAL RESTRAINT SYSTEM CURTAIN SHIELD AIR BAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie down the curtain shield airbag assy LH to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the curtain shield airbag assy LH, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter of at least 1.25 mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the curtain shield airbag assy LH inside the tire
as shown in the illustration.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the curtain shield airbag assy LH coming free
due to the shock from the airbag deployment.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(e) Install the SST(s).
Connect the connectors of the SST(s) to the curtain shield
airbag assy LH.
SST 09082±00802 (09082±10801, 09082±20801)
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H41437
H41438
H40526
H42897
SST(s)
60±50
±
SUPPLEMENTAL RESTRAINT SYSTEM FRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(1) Install the 2 nuts in the front seat airbag assy LH.
(2) Wind the wire harness around the stud bolts of the front seat airbag assy LH as shown in the illustra-
tion.
(3) Position the front seat airbag assy LH inside the tire with the airbag deployment direction facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure the wire harness is tight. It is highly dan-
gerous when looseness in the wire harness results in
the front seat airbag assy LH coming free due to the
shock from the airbag deployment.

Always tie down the front seat airbag assy LH with the
airbag deployment direction facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s). Connect the connector of SST(s) to the front seat airbag
assy LH connect.
SST 09082±00750
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H4263210 m (33 ft) or moreBattery
SST(s)
H42633Weight
X
Y
Y
H40013
Inner Diam.
Tires
(3 or More) Width
60±24
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(2) Move the SST(s) to at least 10 m (33 ft) away from the horn button assy tied down to the disc wheel.
(e) Cover the horn button assy with a cardboard box or tires.

Covering method using a cardboard box:
Cover the horn button assy with the cardboard box
and weigh the cardboard box down in 4 places with
at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
X = 460 mm (18.11 in.)
Y = 650 mm (25.59 in.)
NOTICE:

When the dimension Y of the cardboard box exceeds
the diameter of the disc wheel with tire to which the
horn button assy is tied, X should be the following
size.
X = 460 mm (18.11 in.) + width of tire

If a cardboard box smaller than the specified size is
used, the cardboard box will be broken by the shock
from the airbag deployment.

Covering method using tires:
Place at least 3 tires with no disc wheels on top of
the tire with disc wheel to which the horn button assy
is tied.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:

The tires may be marked by the airbag deployment,
so use a redundant tires.

Do not place the SST(s) connector under the tire be-
cause the SST(s) connector could be damaged.
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H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42664
Inner Diam. WidthTire
60±58
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie down the instrument panel airbag assy to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If the wire harness which is too thin or an alternative object
is used to tie down the instrument panel airbag assy, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter of at least 1.25 mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the instrument panel airbag assy inside the tire
with the airbag deployment side facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the instrument panel airbag assy coming free
due to the shock from the airbag deployment.

Always tie down the instrument panel airbag assy
with the airbag deployment side facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
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H42620
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±33
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the instrument panel passenger airbag assy
(See page 60±29).
CAUTION:

When removing the instrument panel passenger air-
bag assy, work must be started 90 seconds after the
ignition switch is turned to the ºLOCKº position and
the negative (±) terminal cable is disconnected from
the battery.

When storing the instrument panel passenger airbag
assy, keep the upper surface of the airbag deploy-
ment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie down the instrument panel passenger airbag assy to the
tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the instrument panel passenger airbag
assy, it may be snapped by the shock when the airbag is
deployed. This is highly dangerous. Always use a wire har-
ness for vehicle use which has a diameter of at least 1.25
mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the instrument panel passenger airbag assy in-
side the tire with the airbag deployment side facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the instrument panel passenger airbag assy
coming free due to the shock from the airbag deploy-
ment.

Always tie down the instrument panel passenger air-
bag assy with the airbag deployment side facing in-
side the tire.
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700TJ±01
B56435
Slide
B61414
Slide
B66957
Butyl TapeMirror Base
a
b
c
d
70±64
±
WINDSHIELD/WINDOWGLASS/MIRROR INNER REAR VIEW MIRROR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
INNER REAR VIEW MIRROR ASSY
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 INNER REAR VIEW MIRROR ASSY(EC MIRROR)
(a) Remove the inner rear view mirror cover.
(b) Remove the rain sensor covers (See page XX±XXX).
(c) Remove the screw.
(d) Disconnect the connector.
(e) Remove the rear view inner mirror.
2. REMOVE INNER REAR VIEW MIRROR ASSY (NORMAL MIRROR)
(a) Remove the inner rear view mirror, as shown in the il- lustration.
3. INSTALL INNER REAR VIEW MIRROR ASSY (NORMAL MIRROR)
(a) Prepare 2 pieces of butyl tape having the dimensions, as
shown in the illustration.
(b) While extending them until they fit the length of the mirror base (24 mm, (0.944 in.)), apply them to both side of the
mirror base respectively.
(c) Install inner rear view mirror.
NOTICE:
If butyl tape spreads out of the inside groove when applied,
remove the excessive amount of tape so that it will not stick
to the glass. Dimension:
a10 mm (0.393 in.)
b4 mm (0.157 in.)
c6 mm (0.236 in.)
d24 mm (0.944 in.)
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