battery replacement TOYOTA AVENSIS 2003 Service Owner's Manual

600JU±01
±
SUPPLEMENTAL RESTRAINT SYSTEMSUPPLEMENTAL RESTRAINT SYSTEM
60±1
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
PRECAUTION
CAUTION:

AVENSIS is equipped with SRS, which comprises of a driver airbag, front passeng\
er airbag,
side airbag, curtain shield airbag and driver knee airbag. Failure to carry \
out service operations
in the correct sequence could cause the SRS to unexpectedly deploy during \
servicing, possibly
leading to serious accident. Further, if a mistake is made in servicing the SRS, it is possible that
the SRS may fail to operate when required. Before performing servicing (in\
cluding removal or
installation of parts, inspection or replacement), be sure to read the \
following items carefully,
then follow the correct procedures indicated in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the º\
LOCKº position and
the negative (±) terminal cable is disconnected from the battery.
(The SRS is equipped with a back±up power source so that if work is started wi\
thin 90 seconds
after disconnecting the negative (±) terminal cable of the battery, the SRS may be deployed.)

Do not expose the horn button assy, instrument panel passenger airbag assy, instrument panel
airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag
sensor assy, curtain shield airbag assy, airbag sensor rear or seat position airbag sensor di-
rectly to hot air or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so DTCs are th\
e most important in-
formation source of information when troubleshooting. When troubleshooting the SRS, always
inspect DTCs before disconnecting the battery.

Even in the case of a minor collision when the SRS does not deploy, the horn button assy, instru-
ment panel passenger airbag assy, instrument panel airbag assy, airbag sensor assy center,
airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy,
airbag sensor rear and seat position sensor must be inspected (See page 60±11).

Before repairs work, remove the airbag sensor if any kind of shock is likely to occur to the sen-
sor during operation.

Never use SRS parts from another vehicle. When replacing the parts, repl\
ace them with new
ones.

Never disassemble nor repair the horn button assy, instrument panel passenger airbag assy,
instrument panel airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag
assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear or seat position
airbag sensor in order to reuse it.

If the horn button assy, instrument panel passenger airbag assy, instrument panel airbag assy,
airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy,
curtain shield airbag assy, airbag sensor rear or seat position airbag sensor has been dropped,
or if there are any cracks, dents or other defects in the case, bracket \
or connector, replace it
with a new one.

Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting the electrical
circuits circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions the notice.

After work on the SRS is completed, perform the SRS warning light check \
(See page 05±1184).
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610CN±02
B65506
±
SEAT BELT FRONT SEAT BELT
61±7
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:

The installation is in the reverse order of the removal. However, when there is a special point concern-
ing the installation, it is indicated.

Use the same procedures on the LH side as on the RH side.
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT SEAT ASSEMBLY RH
3. REMOVE FRONT SEAT INNER BELT ASSY RH
4.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36, 76±45, 76±54)
5.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36, 76±45, 76±54)
6. REMOVE FRONT DOOR WEATHERSTRIP RH
7. REMOVE REAR DOOR WEATHERSTRIP RH
8.REMOVE CENTER PILLAR GARNISH LOWER RH (See page 76±36, 76±45, 76±54)
9.REMOVE CENTER PILLAR GARNISH UPPER RH (See page 76±36, 76±45, 76±54) 10. REMOVE FRONT SEAT OUTER BELT ASSY RH
NOTICE:

Removal operation concerning the seat belt with the
pretensioner must be started when 90 seconds or
more time has passed after the ignition switch is
turned OFF and the battery negative terminal is dis-
connected.

Carefully read the notices for the ºpretensionerº in
the SRS airbag system section and the front seat out-
er belt assy section.
(a) Remove the nut and the outer belt on the shoulder anchor
side.
(b) Disconnect the pretensioner connector, as shown in the illustration.
(c) Remove the 2 bolts on the retractor side and throughly re- move the outer belt.
11. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSY
(a) Remove the bolt and anchor adjuster.
12. INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSY
(a) Install the adjuster with the bolt. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
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650NC±02
±
LIGHTING LIGHTING SYSTEM
65±1
AVENSIS REPAIR MANUAL (RM1018E)
LIGHTING SYSTEM
PRECAUTION
1. PRECAUTION OF HEADLIGHT BULB REPLACEMENT
(a) When any defects such as deformation, crack, dent, chipping, etc. are identi\
fied on the discharge
headlight (especially, on the light control ECU), replace it with a new one.
(b) Even if the operation seems to be normal, the fail±safe function may \
be defective.
(c) Be careful not to scratch on drop bulbs of the discharge headlamp and halo\
gen bulbs (for headlamp and fog lamp), as they have pressurized gas inside and can be easily broke\
n.
(d) Touching the HV socket of the discharge headlight with the headlight dimmer swit\
ch ON could gener- ate momentary high voltage of 20,000 V and lead to a serious injury.
(e) Never connect a tester to the high voltage socket of the discharge headlight \
for measurement, as this
leads to a serious injury because of high voltage.
(f) When performing operation related to the discharge headlight, keep it away from water including rain, turn off the light control switch, and disconnect the battery terminal and the \
connector of the light control
ECU in advance to avoid electric shock.
(g) When performing operation related to the discharge headlight, start it after\
assembling is completed
and never turn the lights on without a bulb installed.
(h) Do not turn the discharge headlight on using another power source except\
vehicle's.
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670SC±03
67±16
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6)
4.REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) (See page 41±11)
5.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
6.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 67±5)
7.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
8.REMOVE HEATER TO REGISTER DUCT NO.2 (See page 71±11)
9.REMOVE FRONT SEAT ASSY RH (See page POWER SEAT 72±11, MANUAL SEAT72±16)
10.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36)
11.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36)
12.REMOVE COWL SIDE TRIM BOARD RH (See page 76±36)
13.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
14.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
15.REMOVE REAR SEAT CUSHION ASSEMBLY (See page 72±32)
16.REMOVE REAR SEATBACK ASSY (See page 40/60 FOLDING 72±27, UNITED FIXED 72±32)
17.REMOVE ROOF SIDE GARNISH INNER RH (See page 76±36)
18. REMOVE FLOOR CARPET ASSY FRONT
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670SD±02
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (WAGON MODELS)
67±19
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (WAGON MODELS)
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM)
(See page 67±6)
4.REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) (See page 41±11)
5.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
6.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 67±5)
7.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
8.REMOVE HEATER TO REGISTER DUCT NO.2 (See page 71±11)
9.REMOVE FRONT SEAT ASSY RH (See page POWER SEAT 72±11, MANUAL SEAT 72±16)
10.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36)
11.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36)
12.REMOVE COWL SIDE TRIM BOARD RH (See page 76±36)
13.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
14.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
15. REMOVE REAR SEAT CUSHION ASSEMBLY
(See page 40/60 FOLDING FLIP±UP CUSHION72±21, 40/60 FOLDING 72±27)
16. REMOVE REAR SEATBACK ASSY
(See page 40/60 FOLDING FLIP±UP CUSHION72±21, 40/60 FOLDING 72±27)
17. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 40/60 FOLDING FLIP±UP CUSHION72±21, 40/60 FOLDING 72±27)
18. REMOVE TONNEAU COVER ASSY
19.REMOVE BACK DOOR WEATHERSTRIP (See page 76±54)
20.REMOVE DECK BOARD SUB±ASSY (See page 76±54)
21.REMOVE DECK FLOOR BOX REAR (See page 76±54)
22.REMOVE DECK FLOOR BOX FRONT (See page 76±54)
23.REMOVE DECK FLOOR BOX RH (See page 76±54)
24.REMOVE REAR FLOOR FINISH PLATE (See page 76±54)
25.REMOVE DECK TRIM SIDE BOARD RH (See page 76±54)
26.REMOVE ROOF SIDE GARNISH INNER RH (See page 76±54)
27. REMOVE FLOOR CARPET ASSY FRONT
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670SG±02
67±24
±
AUDIO & VISUAL SYSTEM ANTENNA CORD SUB±ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
ANTENNA CORD SUB±ASSY NO.3
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6)
4.REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) (See page 41±11)
5.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
6.REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 67±5)
7.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
8.REMOVE HEATER TO REGISTER DUCT NO.2 (See page 71±11)
9.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36)
10.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36)
11.REMOVE COWL SIDE TRIM BOARD RH (See page 76±36)
12.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
13.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
14. REMOVE REAR SEAT CUSHION ASSEMBLY
(See page 40/60 FOLDING FLIP±UP CUSHION 72±21, 40/60 FOLDING 72±27)
15. REMOVE REAR SEATBACK ASSY (See page 40/60 FOLDING FLIP±UP CUSHION 72±21, 40/60 FOLDING 72±27)
16. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 40/60 FOLDING FLIP±UP CUSHION 72±21, 40/60 FOLDING 72±27)
17.REMOVE PACKAGE TRAY TRIM PANEL ASSY (See page 76±45)
18.REMOVE REAR FLOOR FINISH PLATE (See page 76±45)
19.REMOVE DECK TRIM SIDE PANEL ASSY RH (See page 76±45)
20.REMOVE ROOF SIDE GARNISH INNER RH (See page 76±45)
21.REMOVE FRONT SEAT ASSY RH (See page POWER SEAT 72±11, MANUAL SEAT 72±16)
22. REMOVE FLOOR CARPET ASSY FRONT
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670SI±02
I35212
67±28
±
AUDIO & VISUAL SYSTEMNAVIGATION ANTENNA ASSY
AVENSIS REPAIR MANUAL (RM1018E)
NAVIGATION ANTENNA ASSY
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
3.REMOVE NAVIGATION ANTENNA ASSY
(a)Disconnect the connector.
(b)Remove the 2 screws and navigation antenna assy.
4.INSTALL INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
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670SH±02
I35209
I35210
I35211
±
AUDIO & VISUAL SYSTEMNAVIGATION ECU
67±27
AVENSIS REPAIR MANUAL (RM1018E)
NAVIGATION ECU
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE FRONT SEAT ASSY LH (See page POWER SEAT 72±11, MANUAL SEAT 72±16)
3.REMOVE NAVIGATION ECU COVER
(a)Remove the navigation ECU cover (Front side).
(b)Remove the 3 clips and the navigation ECU cover.
4.REMOVE NAVIGATION COMPUTER W/BRACKET
(a)Remove the 2 bolts.
(b)Disconnect the connectors and remove the navigationcomputer w/ bracket.
5.REMOVE DISC PLAYER BRACKET NO.2
(a)Remove the 2 screws and disc player bracket No.2.
6.REMOVE DISC PLAYER BRACKET NO.3
(a)Remove the 2 screws and disc player bracket No.3.
7.REMOVE NAVIGATION ECU
8.INSTALL FRONT SEAT ASSY LH (See page POWER SEAT 72±11, MANUAL SEAT 72±16)
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670S6±02
I35191
I35165
I35166
±
AUDIO & VISUAL SYSTEMRADIO RECEIVER ASSY
67±5
AVENSIS REPAIR MANUAL (RM1018E)
RADIO RECEIVER ASSY
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 71±11)
3.REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 71±11)
4.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
5.REMOVE RADIO RECEIVER ASSEMBLYW/BRACKET
(a)Remove the 4 bolts.
(b)Disconnect the connector and remove the radio receiver assy w/ bracket.
6.REMOVE RADIO BRACKET NO.1
(a)Remove the 6 screws and radio bracket No.1.
7.REMOVE RADIO BRACKET NO.2
(a)Remove the 6 screws and radio bracket No.2.
8.REMOVE AIR CONDITIONING CONTROL ASSY (See page 55±50)
9. REMOVE RADIO RECEIVER ASSY
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730EW±02
I15123
I15122
±
THEFT DETERRENT & DOOR LOCKTRANSMITTER BATTERY
73±17
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMITTER BATTERY
REPLACEMENT
1.REMOVE TRANSMITTER SUB±ASSY MODULE SET DOOR CONTROL (See page 73±18)
NOTICE:
Special caution should be taken for handling each component as they are precisi\
on electronic com-
ponents.
2. REMOVE TRANSMITTER BATTERY
(a) Remove the cover.
(b) Remove the transmitter battery (lithium battery).
NOTICE:

Do not push the terminals with your finger.

Prying up the battery (lithium battery) to forcibly re-
move it will cause deformation of the terminals.

Do not touch the battery with wet hands. Water may
cause unexpected rust.

Do not touch or move any components inside the
transmitter as it may interfere with proper operation.
3. INSTALL TRANSMITTER BATTERY
(a) Install a new battery (lithium battery) with the positive (+) side up, as shown in the illustration.
NOTICE:

Be sure that the positive side and the negative side of
the transmitter battery are matched±up correctly.

Be careful not to bend the electrode of the transmitter
battery insertion.

Be careful that dust or oil does not adhere to the trans-
mitter case.
(b) Install the cover.
NOTICE:
If the screws are loose, it may cause faulty contact between
the battery (lithium battery) and the terminals.
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