torque TOYOTA AVENSIS 2003 Service User Guide

010B2±13
N17080
Filler Cap
Float
Reservoir Tank
Grommet
Clip
Slotted Spring Pin
: Specified torque

Non±reusable part Cylinder
Piston
Push Rod
Washer
Snap Ring
Boot


Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
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INTRODUCTION HOW TO USE THIS MANUAL
01±1
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking \
and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ºDiagnosisº (found in the ºDiagnosticsº section), the 2nd
pro-
cess of ºRemoving and Installing, Replacing, Disassembling, Installing and Ch\
ecking, and Adjustingº,
but the 3rd process of ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a refe\
rence to help you find the item to be repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM\
) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are requir\
ed and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed under the title where necessary.
(b) Non±reusable parts, grease application area, precoated parts and tigh\
tening torque are specified in the component drawings.
Example:
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Illustration:what to do and where
Component part No.
Detailed text: how to perform task
Task heading: what to do
Set part No
D31009
01±2
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INTRODUCTION HOW TO USE THIS MANUAL
AVENSIS REPAIR MANUAL (RM1018E)
(c) Tightening torque, grease application area, and non±reusable parts are described as important points in the procedures.
NOTICE:
There are cases where such information can only be explained by using an illu\
stration. In these
cases, all the information such as torque, oil, etc. are described in the illu\
stration.
(d) Installing procedures are performed in the reverse order of the removal and only the important points are described.
(e) Only items with points are described in the procedure, and the operational portion \
and content are placed using an illustration. In the explanations, details of the operational \
method, standard value and
notices are placed.
(f) There may be a case where the illustrations of similar models are used. In th\
at case, specific details may be different from the actual vehicle.
(g) The procedures are presented in a step±by±step format: (1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task and gives other information such as specifica-tions and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary and the text below provides deta\
iled information. Important
specifications and warnings always are written in bold type to stand out from the rest\
of the text.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce- dure to look up your specifications. The specifications are also found in th\
e Service Specifications sec-
tion for quick reference.
6. TERMS DEFINITION
CAUTIONIndicates the possibility of injury to you or other people.
NOTICEIndicates the possibility of damage to the components being repaired.
HINTProvides additional information to help you to perform the repair efficiently.
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INTRODUCTION HOW TO USE THIS MANUAL
01±3
AVENSIS REPAIR MANUAL (RM1018E)
7. SI UNIT
(a) The units given in this manual are primarily expressed according to the SI \
UNIT (International System
of Units), and alternately expressed in the metric system and in the Engl\
ish System.
Example:
Torque: 30 N
m (310 kgf
cm, 22 ft
lbf)
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Z11554
Seal Lock Adhesive
BE1367
Medium Current Fuse and High Current
Fuse Equal Amperage Rating


V35002
IllustrationSymbol Part Name Abbreviation
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE FUSE
M±FUSE H±FUSE
01±6
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INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to li\
ft and support thevehicle at the proper locations (See page 01±19).
(c) PRECOATED PARTS(1) Precoated parts such as bolts, nuts, etc., are
coated with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry the part with compressed air.
Then apply the specified seal lock adhesive to the
bolt, nut or threads.
NOTICE:
Check the torque with the lower limit value of the torque tol-
erance.
(4) Depending on the seal lock agent to be applied,there may be cases where it is necessary to leave
it for a specified time until it hardens.
(d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always u\
se a torque wrench.
(f) FUSES(1) When replacing fuses, be sure that a new fuse hasthe correct amperage rating. DO NOT exceed the
rating, or use one with a lower rating.
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L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
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INTRODUCTIONREPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE (1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.
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INTRODUCTION TERMS
01±43
AVENSIS REPAIR MANUAL (RM1018E)
HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module±
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel±Shutoff±
ISCIdle Speed Control±
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure±
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature±
MVZManifold Vacuum Zone±
NVRAMNon±Volatile Random Access Memory±
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn±Board DiagnosticOn±Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module±
PNPPark/Neutral Position±
PROMProgrammable Read Only Memory±
PSPPower Steering Pressure±
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module±
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE±ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter±
SRIService Reminder Indicator±
SRTSystem Readiness Test±
STScan Tool±
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
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022KX±01
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PREPARATION AUDIO & VISUAL SYSTEM
02±55
AVENSIS REPAIR MANUAL (RM1018E)
AUDIO & VISUAL SYSTEM
PREPARATION
Recomended Tools
09042±00010Torx Socket T30NAVIGATION ANTENNA ASSY
09042±00030Torx Socket T20CIGARETTE LIGHTER ASSY
09050±00032Air DrillFRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
(09050±00210)Chuck SetFRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
(09050±00220)HandleFRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
09050±20010Air RiveterFRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
(09050±02010)Dust CapFRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
(09050±02020)Nose Piece No.1FRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
09060±60350Revet CutterFRONT NO.1 SPEAKER ASSY
REAR SPEAKER ASSY
09070±20010Moulding RemoverRADIO RECEIVER ASSY
ANTENNA CORD SUB±ASSY
POWER POINT SOCKET ASSY
NAVIGATION ANTENNA ASSY
ANTENNA CORD SUB±ASSY NO.3
AMPLIFIER ANTENNA
ASSY(LIFTBACK MODELS)
AMPLIFIER ANTENNA ASSY(SEDAN
MODELS)
AMPLIFIER ANTENNA
ASSY(WAGON MODELS)
Equipment
Torque wrench
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PREPARATION AUTOMATIC TRANSMISSION / TRANS
02±37
AVENSIS REPAIR MANUAL (RM1018E)
(09316±00011)Replacer PipeFRONT DIFFERENTIAL OIL
SEAL(U241E)
09350±32014TOYOTA Automatic Transmission
Tool SetTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09351±32010)One±way Clutch Test ToolTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
(09351±32020)Stator StopperTORQUE CONVERTER CLUTCH
AND DRIVE PLATE(ATM)
AUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09520±01010Drive Shaft Remover AttachmentAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09520±24010Differential Side Gear Shaft
PullerAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
(09520±32040)Shocker SetAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09554±14010Differential Oil Seal ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)
09628±62011Boll Joint PullerAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09649±17010Steering Knuckle ToolFRONT DIFFERENTIAL OIL
SEAL(U241E)
09726±27012Front Suspension Arm Bushing
Remover & ReplacerFRONT DIFFERENTIAL OIL
SEAL(U341E)
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PREPARATION AUTOMATIC TRANSMISSION / TRANS
02±39
AVENSIS REPAIR MANUAL (RM1018E)
09090±04020Engine Sling DeviceAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
95416±00140Gas Leak Detector
(Halogen Leak Detector)
(DENSO Part No.)TRANSMISSION CONTROL CABLE
ASSY
09216±00021Belt Tension GaugeAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
SSM
08833±00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentTRANSMISSION WIRE(U241E)
TRANSMISSION VALVE BODY
ASSY(U241E)
Equipment
Straight edgeAutomatic transaxle assy
Torque wrench
Vernier calipersAutomatic transaxle assy
Dial indicator with magnetic baseTorque converter and drive plate
Slide calipersAutomatic transaxle assy
Chain blockAutomatic transaxle assy
Lubricant
U341E
Automatic transaxle fluid
Dry fill
Drain and refill
6.9 liter (7.7 USqts, 6.4 lmp.qts)
3.0 liter (3.2 USqts, 2.6 lmp.qts)ATF type T±IV
U241F
Automatic transaxle fluid
Dry fill
Drain and refill
8.6 liter (9.0 USqts, 7.6 lmp.qts)
3.5 liter (3.7 USqts, 3.1 lmp.qts)ATF type T±IV
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02±34
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PREPARATION BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
Equipment
Micrometer
Dial indicator w/ magnetic base
Brake drum gauge
Slide calipers
Torque wrench
Lubricant
ItemCapacityClassification
Brake fluid±SAE J1704 or FMVSS No. 116 DOT4
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