Control panel TOYOTA AVENSIS 2003 Service User Guide

A79178
A78277
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±287
AVENSIS REPAIR MANUAL (RM1018E)
24.SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a)Remove the 2 clips and 2 washers, separate the control cable assy.
25.REMOVE INJECTOR DRIVER
(a)Remove the 2 nuts which is used to secure the injector driver.
(b)Disconnect the injector driver connector and the harness clamp.
(c)Remove the injector driver.
26.DISCONNECT ENGINE WIRE
(a)Remove the glove compartment door.
(b)Disconnect the engine wire from the ECM and the junc-
tion block.
(c)Pull out the engine wire.
(d)Disconnect the engine wire from engine room junction block.
(e)Remove the bolt and disconnect the wire harness from the body.
27.REMOVE AIR TUBE NO.1
(a)Loosen the hose clamps.
(b)Remove the 2 bolts and nut, and then detach the air tube No. 1.
28.REMOVE CLUTCH ACCUMULATOR ASSY (See page 42±17) SST 09023±00100
29.REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 42±17)
30. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 14±269)
31. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See page 55±86)
HINT:
Secure the hoses off to the side instead of detaching.
32.REMOVE FLOOR PANEL BRACE FRONT (See page 15±10)
33.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±10)
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A77338
A79320
A79296
A60622
14±30
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
32. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See page 41±15)
33. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
(See page 41±15)
34. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)
35.SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
36.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
37. REMOVE INSTRUMENT PANEL UNDER COVER SUB±ASSY NO.2
38. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the ECM and junctionblock.
(b) Pull out the engine wire.
(c) Remove the engine room relay block No.2 cover.
(d) Remove a nut and disconnect a connector as shown in the illustration.
(e) Remove the bolt and disconnect the ground terminal.
(f) Disconnect the ground terminal connector.
(g) Remove the nut and disconnect the battery terminal B.
39. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
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A76717
A
B
A
B
A76716
AA
BBBBBB
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±43
AVENSIS REPAIR MANUAL (RM1018E)
(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N
m (459 kgf
cm, 33 ft
lbf) for Bolt A
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Nut B
(f) Install the front suspension member brace LH and RH with the 8 bolts.
Torque:
133 N
m (1,356 kgf
cm, 98 ft
lbf) for Bolt A
80 N
m (816 kgf
cm, 59 ft
lbf) for Bolt B
NOTICE:
When installing the crossmember, check that the position-
ing holes on the crossmember and on the vehicle are
aligned with each other.
122.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
123. INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
124.INSTALL FRONT STABILIZER LINK ASSY LH (See page 30±6)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
126.INSTALL TIE ROD END SUB±ASSY LH (See page 30±6)
127. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
128.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
129. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
130.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±2)
131. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
132.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
133.INSTALL GENERATOR ASSY (See page 19±7)
134. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:

1ZZ±FE (See page 55±74)

3ZZ±FE (See page 55±70)
135. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See page 41±15)
136. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See page 40±11)
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INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±9
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)Abbreviations Meaning
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick±Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft±Hand
LHDLeft±Hand Drive
L/H/WLength, Height, Width
LLCLong±Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
NO.Number
O2SOxygen Sensor
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
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270E8±01
G25771
G25772
27±8
±
REAR SUSPENSION REAR SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
REAR SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:
COMPONENTS: See page 27±2.
1. REMOVE REAR DOOR SCUFF PLATE LH
2. REMOVE REAR SEAT CUSHION ASSEMBLY
(a)40/60 FOLDING FLIP±UP CUSHION (See page 72±21)
(b)40/60 FOLDING (See page 72±27)
(c)UNITED FIXED (See page 72±32)
3. REMOVE REAR SEATBACK ASSY
(a)40/60 FOLDING FLIP±UP CUSHION (See page 72±21)
(b)40/60 FOLDING (See page 72±27)
(c)UNITED FIXED (See page 72±32)
4. REMOVE REAR FLOOR FINISH PLATE (SEDAN MODELS)
5. REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH (SEDAN MODELS)
6. REMOVE REAR FLOOR FINISH PLATE (LIFTBACK MODELS)
7.REMOVE DECK TRIM SIDE BOARD LH (LIFTBACK MODELS) (See page 76±45)
8. REMOVE REAR FLOOR FINISH PLATE (WAGON MODELS)
9.REMOVE DECK TRIM SIDE PANEL ASSY LH (WAGON MODELS) (See page 76±54)
10. REMOVE REAR WHEEL 11. DISCONNECT SKID CONTROL SENSOR WIRE
(a) Disconnect the skid control sensor connector.
(b) Remove the bolt and wire bracket.
12. SEPARATE REAR STABILIZER LINK ASSY LH
(a) Remove the nut, and separate the rear stabilizer link assyLH.
HINT:
If the ball joint turns together with the nut, use a hexagon (5 mm)
wrench to hold the stud.
13. SEPARATE REAR STABILIZER LINK ASSY RH
HINT:
Separate the RH side by the same procedures as the LH side.
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4105U±03
D30489
Gasoline Engine:Front Floor
Heat Insulator No.1
Console Box Carpet
Floor Shift Lever Knob
Sub±assy
Console Panel Sub±assy Upper
Console Panel Sub±assy Lower
Console Box Sub±assy Rear
Clip
Clip
Clip
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
ClipClip
12 (122, 9)
Floor Shift Shift Lever Assy
12 (122, 9)
N´m (kgf´cm, ft´lbf) : Specified torque
5.5 (56, 49 in.

lbf)
Transmission Control Cable Assy
41±10
±
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
FLOOR SHIFT SHIFT LEVER ASSY (MTM)
COMPONENTS
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410DR±01
D26893
D26895
D30474
D30474
±
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
41±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB±ASSY (See page 71±11)
2.REMOVE CONSOLE PANEL UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY REAR (See page 71±11)
5. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the cable ends of the controlcable assy.
(b) Release the claws, separate the control cable assy.
6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY
(a) Remove the 4 bolts and shift lever assy.
7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY
(a) Install the shift lever assy with the 4 bolts. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
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4105R±02
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
D30070
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±7
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION CONTROL CABLE ASSY (MTM)
REPLACEMENT
HINT:
COMPONENTS: See page 41±10
1.REMOVE AIR CONDITIONER UNIT ASSY (See page 55±55)
HINT:
Refer to the instructions for removal of the instrument panel sub±ass\
y lower.
2. REMOVE EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and heat insulator No.1.
4. REMOVE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the 2 cables from the trans-axle.
(b) Remove the 2 clips, separate the 2 cables from the brack- et.
(c) Remove the 2 nuts, separate the control cable assy.
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550YT±01
I35273
Manual A/C:Heater Control HousingAir Conditioning Control Assy
Air Conditioning Control Bulb Heater Control Housing Sub±assy
Heater Control Lens Assy
Heater Control Housing Heater Control Knob No.2
Heater Control Knob No.3 Heater Control Knob
Cooler Wire No.1
Air Conditioning Panel Sub±assy
55±48
±
HEATER & AIR CONDITIONER AIR CONDITIONING CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING CONTROL ASSY
COMPONENTS
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I35274
Auto A/C:Air Conditioning Control Assy
Cooler Wire No.1
Heater Control Housing
Control Knob Sub±assy
Air Conditioning Panel Sub±assy
±
HEATER & AIR CONDITIONER AIR CONDITIONING CONTROL ASSY
55±49
AVENSIS REPAIR MANUAL (RM1018E)
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