TOYOTA AVENSIS 2003 Service Repair Manual

B67034
Primer Ga
a
b
a ± a
c ± c
c
b
b ± b c
Backside
Primer GPrimer G
B67035
A
B aa
b
b
A ± A
C ± C
B ± B
B
A
C
Backside
ba
c
C
c
a b
BO2821
70±20
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
HINT:
If an area other than that specified is coated by accident, wipe
off the primer with a clean shop rag before it dries.
NOTICE:

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

Do not keep any of the opened Primer G for later use.
(e) Apply adhesive. Adhesive: Part No. 08850±00801 or equivalent
(1) Cut off the tip of the cartridge nozzle, as shown inthe illustration.
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
Tackfree time:
TemperatureTackfree Time
35C (95 F)15 minutes
20C (68 F)1 hour 40 minutes
5C (41 F)8 hours
(2) Load the sealer gun with the cartridge.
(3) Coat the glass with adhesive, as shown in the il-
lustration.
Standard dimension:
a12.5 mm (0.492 in.)
b8.0 mm (0.315 in.)
c3.0 mm (0.118 in.)
(f) Install the glass to the body. (1) Using a suction cup, position the glass so that thereference marks are aligned, and press it in gently
along the rim.
NOTICE:

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

Check that the stoppers are attached to the vehicle
body correctly.

Check the clearance between the vehicle body and
glass.
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BO3986
Adhesive
N08495
Adhesive
WindshieldDam
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS
70±21
AVENSIS REPAIR MANUAL (RM1018E)
(2) Lightly press the front surface of the glass to ensure
a close fit.
(3) Using a scraper, remove any excess or protruding adhesive.
HINT:
Apply adhesive onto the glass rim.
NOTICE:
Take care not to drive the vehicle for the time described in
the table below. Minimum time:
TemperatureMinimum time prior to driving vehicle
35
C (95
F)1 hour 30 minutes
20
C (68
F)5 hours
5
C (41
F)24 hours
14. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the adhesive has completely hardened.
(b) Seal any leaks with auto glass sealer.
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710CM±02
±
INSTRUMENT PANEL/METERCOMBINATION METER
71±1
AVENSIS REPAIR MANUAL (RM1018E)
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Discharge warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Brake warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
ABS warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
SRS warning light does not come on.
1.Wire Harness or Connector
2.Airbag Sensor Assy
3.Combination Meter Assy±
05±1197 ±
Open Door warning light does not come on.
1.Wire Harness or Connector
2.Front Door Courtesy Light
3.Body ECU
4.Combination Meter Assy±
±
±
±
Fuel Level warning light does not come on.
1.Wire Harness or Connector
2.Fuel Sender Gauge
3.Combination Meter Assy±
±
±
Low Oil Pressure warning light does not come on.
1.Wire Harness or Connector
2.Low Oil Pressure Warning Switch
3.Combination Meter Assy±
±
±
Engine Oil Level warning light does not come on.
1.Wire Harness or Connector
2.Oil Level Sensor
3.Combination Meter Assy±
±
±
Belt warning light does not come on.
1.Wire Harness or Connector
2.Body ECU
3.Front Inner Belt Assy
4.Combination Meter Assy±
±
05±1522
±
VSC warning light does not come on.
1.Wire Harness or Connector
2.VSC Circuit
3.Combination Meter Assy±
05±752 ±
Indicator Lights:
SymptomSuspect AreaSee page
Shift indicator light do not come on.
1. Wire Harness or Connector
2. ECM
3. Neutral Start Switch Circuit
4. Combination Meter Assy±
±
±
±
Turn indicator light does not come on.
1. Wire Harness or Connector
2. Turn Signal and Hazard Warning System
3. Combination Meter Assy±
65±9 ±
Glow indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy±
±
±
TRC off indicator light does not come on.
1. Wire Harness or Connector
2. VSC Circuit
3. Combination Meter Assy±
05±752 ±
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71±2
±
INSTRUMENT PANEL/METERCOMBINATION METER
AVENSIS REPAIR MANUAL (RM1018E)
SLIP indicator light does not come on.
1.Wire Harness or Connector
2.Skid Control ECU
3.Combination Meter Assy±
05±752 ±
CRUISE indicator light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
High Beam indicator light does not come on.
1.Wire Harness or Connector
2.Headlight Dimmer Switch
3.Combination Meter Assy±
65±9 ±
Fr FOG indicator does not come on.
1.Wire Harness or Connector
2.Fr FOG Relay
3.Fr FOG Light Switch
4.Combination Meter Assy±
±
±
±
Rr FOG indicator does not come on.
1.Wire Harness or Connector
2.Rr FOG Relay
3.Rr FOG Light Switch
4.Combination Meter Assy±
±
±
±
TAIL indicator does not come on.
1.Wire Harness or Connector
2.TAIL Relay
3.Combination Meter Assy±
±
±
WATER LEVEL indicator does not come on (1KD±FTV).
1.Wire Harness or Connector
2.Water Level Sensor
3.Combination Meter Assy±
±
±
EMPS indicator does not come on.
1.Wire Harness or Connector
2.EMPS ECU
3.Combination Meter Assy±
±
±
A/T OIL TEMP indicator does not come on.
1.Refer to troubleshooting
2.Wire Harness or Connector
3.Combination Meter Assy05±856
±
±
ECT SNOW indicator does not come on.
1.Refer to troubleshooting
2.Wire Harness or Connector
3.Combination Meter Assy05±980±
±
AUTO LEVELING indicator does not come on.
1.Wire Harness or Connector
2.Auto Leveling ECU
3.Combination Meter Assy±
±
±
Meter Gauges:
SymptomSuspect AreaSee page
Speedometer does not operate.1.Refer to troubleshooting05±1510
Water temperature does not operate.1.Refer to troubleshooting05±1515
Tachometer does not operate.1.Refer to troubleshooting05±1513
Fuel Gauge does not operate or operates abnormally.1.Refer to troubleshooting05±1517
OTHERS:
SymptomSuspect AreaSee page
key reminder buzzer does not operate.
1. Wire Harness or Connector
2. Body ECU (KSW, DCTY)
3. Door Coutesy Switch
4. Key Unlock Warning Switch
5. Combination Meter Assy±
±
±
05±1586 ±
Light reminder buzzer does not operate.
1. Wire Harness or Connector
2. Body ECU (DCTY)
3. Combination Meter Assy±
±
±
Seat belt Warning buzzer does not operate.
1. Perform DATA LIST with hand±held tester
2. Wire Harness or Connector
3. Seat Belt Buckle Switch
4. Combination Meter Assy05±1499±
61±3
±
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710CN±02
I34628
C10±19
C10±5
±
INSTRUMENT PANEL/METER COMBINATION METER
71±3
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT SPEEDOMETER
(a) Check the operation.
(1) Using a speedometer tester, inspect the speedometer for acceptable indication error and checkthe operation of the odometer.
Reference: km/h (Europe)
Standard indicationAcceptable range
20 km/h21.0 ± 25.0 km/h
40 km/h41.7 ± 46.2 km/h
60 km/h62.7 ± 67.2 km/h
80 km/h83.4 ± 88.4 km/h
100 km/h104.3 ± 109.3 km/h
120 km/h125.1 ± 130.6 km/h
140 km/h145.8 ± 151.8 km/h
160 km/h166.2 ± 173.2 km/h
180 km/h186.9 ± 194.5 km/h
200 km/h207.7 ± 215.7 km/h
220 km/h228.4 ± 236.8 km/h
240 km/h249.2 ± 258.0 km/h
Reference: MPH (Europe)
Standard indicationAcceptable range
20 mph21.0 ± 23.5 mph
40 mph42.0 ± 44.5 mph
60 mph62.5 ± 66.0 mph
80 mph83.1 ± 87.1 mph
100 mph103.9 ± 108.4 mph
120 mph124.7 ± 129.6 mph
140 mph145.4 ± 150.7 mph
NOTICE:
Tire wear and over or under inflation will affect the indication error. (2) Check the deflection width of the speed meter indicator.
Reference: Below 0.5 km/h (0.3 mph)
2. INSPECT OUTPUT SIGNAL OF VEHICLE SPEED
(a) Check for the signal.(1) While driving the vehicle at the speed of 10 km/h,check the voltage between the terminal C11±15 of
the combination meter assy and the body ground.
Standard: Fluctuation between 10 to 14 V or less is re-
peated 7 times within 1 sec.
NOTICE:
Check it with the ignition switch ON and the connector con-
nected.
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I30899
Fuel Sender Gauge:
71±4
±
INSTRUMENT PANEL/METER COMBINATION METER
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT TACHOMETER
(a) Check the operation (1) Connect a tune±up test tachometer, and start the engine.
NOTICE:

Reversing the connection of the tachometer will damage the transistors and the insides of the
diodes .

When removing or installing the tachometer, be careful not to drop or subject it to heavy
shocks.
(2) Compare the result of the test with standard indication.
DC 13.5 V, 25 C at (77 F)
Standard indication (r/min)Acceptable range (r/min)
Data in ( ) are for reference
700630 ± 770
1,000(900 ± 1100)
2,000(1850 ± 2150)
3,0002800 ± 3200
4,000(3800 ± 4200)
5,0004800 ± 5200
6,000(5750 ± 6250)
7,0006700 ± 7300
4. INSPECT FUEL RECEIVER GAUGE
(a) Inspect the circuit. (1) Disconnect the connector from the sender gauge.
(2) Turn the ignition switch to ON, then check the posi-tion of the receiver gauge needle.
Needle position: EMPTY
(3) Connect the terminal 2 and 3 on the wire harness side connector of fuel sender gauge.
(4) Turn the ignition switch to ON, then check the posi- tion of the receiver gauge needle.
Needle position: FULL
5. INSPECT FUEL LEVEL WARNING
(a) Inspect the circuit. (1) Disconnect the connector from the sender gauge.
(2) Turn the ignition switch to ON, check the fuel level needle indicates EMPTY \
and fuel level warn-ing light comes on.
6. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE WARNING LIGHT
(a) Inspect the circuit. (1) Disconnect the connector from the sender gauge.
(2) Turn the ignition switch to ON, check the position of the water temperature \
receiver gaugeneedle.
Needle position: COOL
(3) Ground the terminal 2 on the wire harness side, then check the position of the\
water temperature receiver gauge needle.
Needle position: HOT
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IG
SPEED
BKL SW
(D±seat)
BKL SW
(P seat)
WRN LAMP
BUZZERON
OFF
15km/h
0
BELT ON
BELT OFF
LVL1
LVL2 BELT ON
BELT OFF
ON
OFF OFF
30s
90s30s90s
±
INSTRUMENT PANEL/METER COMBINATION METER
71±5
AVENSIS REPAIR MANUAL (RM1018E)
7. INSPECT SEAT BELT WARNING LIGHT & BUZZER
(a) Check the operation.
(1) Turn the ignition switch to ON and check that the warning light comes on.\
(2) Fasten the outer belt to the inner belt and check that the warning light\
goes out.
(3) Disconnect the connector from the buckle switch and ground the terminal \
on the wire harness
side connector.
(4) Turn the ignition switch to ON and check that the warning light comes on.\
8. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Inspect the circuit. (1) Disconnect the connector from the low oil pressure switch.
(2) Turn the ignition switch to ON.
(3) Ground the terminal of the wire harness side connector, then check the low oil pressure warninglight.
Low oil pressure warning light: Come on
9. INSPECT BRAKE WARNING LIGHT
(a) Inspect the parking brake warning light.
(1) Disconnect the connector from the parking brake switch and ground the terminal on the wire har-ness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
(b) Inspect the brake fluid level warning light.
(1) Disconnect the connector from the brake fluid level warning switch and c\
onnect the terminalson the wire harness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
10. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Inspect the continuity.
(1) Remove the reservoir tank cap and strainer.
(2) Disconnect the connector.
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71±6
±
INSTRUMENT PANEL/METERCOMBINATION METER
AVENSIS REPAIR MANUAL (RM1018E)
(3)Check that the continuity exists between the terminals.
Float up (switch off): No continuity
(4)Use a syphon, etc., to take fluid out of the reservoir tank.
(5)Check that the continuity exists between the terminals.
Float down (switch on): Continuity
(6)Pour the fluid back in the reservoir tank.
(7)Reconnect the connector.
(8)Check that the buzzer stop after about 4 to 8 seconds.
11.INSPECT KEY REMINDER WARNING BUZZER
(a)Check warning buzzer function. (1)Turn the ignition switch ON and check that the key reminder warning sounds i\
f the ignition keyis insert the key cylinder and front driver side door is opened (See Page 05±1586).
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710G0±01
B660342 Clips
B660407 Claws
±
INSTRUMENT PANEL/METERCOMBINATION METER ASSY
71±21
AVENSIS REPAIR MANUAL (RM1018E)
COMBINATION METER ASSY
OVERHAUL
1.REMOVE STEERING COLUMN COVER LWR (See page 50±9)
2.REMOVE STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(See page 50±9)
3. REMOVE COMBINATION METER ASSY
(a) Remove the 2 screws and disengage the 2 clips.
(b) Pull out the combination meter assy, then disconnect theconnectors.
4. REMOVE COMBINATION METER GLASS
(a) Remove the 2 screws.
(b) Disengage the 7 claws and remove the combination me- ter glass.
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710G2±01
B66037
Front Pillar Garnish LHFront Pillar Garnish RH
Instrument Panel Register
Assy No.2
Instrument Panel Register
Assy No.1
Steering Column Cover
w/ Instrument Cluster Finish Panel Assy Combination Meter Assy
Glove Compartment
Door AssyGlove Compartment
Door Stopper Sub±assy
w/ Multi±Display: w/ Box:
w/ Navi:
Instrument Panel Register Assy CTRInstrument Cluster Finish
Panel Garnish No.2
Steering
Column Cover LWR
Instrument Cluster Finish
Panel Garnish No.1
Combination Meter Glass
N´m (kgf´cm, ft´lbf) : Specified torque
A
G
H
H
HHHHHH
20 (200, 14)
±
INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER
71±7
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL/METER
COMPONENTS
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