relay TOYOTA AVENSIS 2003 Service Owner's Manual

141BF±01
A77281
A77301
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
14±121
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE FUEL SYSTEM PRESSURE (See page 11±19)
2.REMOVE FRONT WHEELS
3.REMOVE RADIATOR SUPPORT OPENING COVER
4.REMOVE ENGINE ROOM COVER SIDE
5.REMOVE ENGINE UNDER COVER RH
6.REMOVE ENGINE UNDER COVER LH
7.DRAIN COOLANT (See page 16±19)
8.DRAIN ENGINE OIL
(a)Install a new gasket and the drain plug after draining engine oil.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
9.DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE) Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (See page 40±2)
11.REMOVE ENGINE COVER SUB±ASSY NO.1
(a)Remove 2 nuts and the cylinder head cover No. 1.
12.DISCONNECT RADIATOR HOSE INLET
13.DISCONNECT RADIATOR HOSE OUTLET 14.SEPARATE RADIATOR RELAY BLOCK
(a)Remove 2 bolts and separate the radiator relay block.
15.SEPARATE COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD(W/ AIR CONDITIONER) STEERING POSITION TYPE)
(a)Remove a bolt and separate the suction hose No. 1.
16.REMOVE RADIATOR ASSY (See page 16±24)
17.REMOVE FAN AND GENERATOR V BELT (See page 14±105)
18.REMOVE GENERATOR ASSY (See page 19±20)
19. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
(a) Remove 4 bolts and separate the compressor and magnetic clutch.
HINT:
Secure the hoses off to the side instead of detaching.
http://vnx.su

A77338
A77337
A77336
A57550
Engine Hanger No. 1 Engine Hanger No. 2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1AZ±FE)
14±125
AVENSIS REPAIR MANUAL (RM1018E)
55. SEPARATE ENGINE ROOM RELAY BLOCK NO.2
(a) Remove the nut and disconnect the connector as shown
in the illustration.
56. SEPARATE ENGINE WIRE
(a) Remove the bolt and separate the grand terminal.
(b) Separate the grand terminal connector.
(c) Remove the glove compartment door panel.
(d) Separate the engine wire.
57.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9) 58. INSTALL ENGINE HANGERS
(a) Install the engine hanger No. 1 (12281±28010, 28020,28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Install the engine hanger No. 2 (12282±28010, 28020, 28030) with the bolt (91512±61020).
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
http://vnx.su

14±134
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
155.INSTALL RADIATOR ASSY (See page 16±24)
156.INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
157.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm,62 in.
lbf)
158.ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
159.ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
160.ADD ENGINE OIL
161.ADD COOLANT (See page 16±19)
162. ADD POWER STEERING FLUID
163. BLEED POWER STEERING FLUID
164. CHECK FOR ENGINE OIL LEAKS
165.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
166.CHECK FOR FUEL LEAKS (See page 11±15)
167. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
168.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
169.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±101)
170.INSPECT CO/HC (See page 14±101)
171. CHECK ABS SPEED SENSOR SIGNAL
http://vnx.su

141C3±01
A79198N´m (kgf´cm, ft´lbf): Specified torque
5.0 (51, 44 in.
lbf)
19 (194, 14)
3.0 to 4.0 (31 to 41, 27 to 35 in.
lbf)
7.0 (71, 62 in.
lbf)
5.3 (54, 47in.
lbf)
Engine Room Relay Block No. 3
8.0 (82, 71 in.
lbf)
Engine Room Cover Side
Radiator Support Opening Cover
Radiator Support Upper Radiator Hose Inlet
Engine Cover No. 1
Radiator Hose Outlet w/ A/C:
Radiator Assy
Battery Battery Tray Engine Under Cover RH Engine Under Cover Sub±assy No. 1
Engine Under Cover LH
Air Cleaner Cap w/ Hose
Air Cleaner Element
Air Cleaner Case
Clip
Clip
Clip
Retainer
Clip
Clip
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
14±277
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1CD±FTV)
COMPONENTS
http://vnx.su

141C4±01
A80094
14±286
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT WHEELS
2.REMOVE ENGINE UNDER COVER LH
3.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
4.REMOVE ENGINE UNDER COVER RH
5.REMOVE RADIATOR SUPPORT OPENING COVER
6.REMOVE ENGINE ROOM COVER SIDE
7.DRAIN ENGINE COOLANT (See page 16±44)
8.DRAIN ENGINE OIL (See page 14±342)
9.DRAIN MANUAL TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm,36 ft
lbf)
10.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
11.REMOVE BATTERY
12.REMOVE AIR CLEANER ASSY
(a)Disconnect the connector.
(b)Remove the air cleaner cap together with the air cleaner hose.
(c)Remove the air cleaner filter element.
(d)Remove the 3 bolts and the air cleaner case.
13.DISCONNECT UNION TO CONNECTOR TUBE HOSE
14.REMOVE FUEL FILTER ASSY
(a)Disconnect the 2 fuel hose from the fuel filter (STD).
(b)Disconnect the 3 fuel hose from the fuel filter (COLD).
(c)Disconnect the connector (STD).
(d)Disconnect the 2 connectors (COLD).
(e)Remove the 2 bolts and the fuel filter.
15.REMOVE RADIATOR HOSE INLET
16.REMOVE RADIATOR HOSE OUTLET
17.DISCONNECT WATER BY±PASS HOSE NO.2
18.REMOVE ENGINE ROOM RELAY BLOCK NO.3
(a)Remove the 2 bolts and the engine room relay block.
19.REMOVE RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
20. DISCONNECT HEATER INLET WATER HOSE
21. DISCONNECT HEATER OUTLET WATER HOSE
22. DISCONNECT FUEL HOSE NO.2
23. REMOVE AIR TUBE NO.2
(a) Loosen the hose clamp and disconnect the air hose No.3.
(b) Remove the 2 bolts and the air tube No. 2.
http://vnx.su

A64328
2 to 7 mm0 to 2 mm
A78274
Upward
90

Clamp
Bolt
A64328
2 to 7 mm 0 to 4 mm
A64007
Front
90

Clamp
Bolt
±
ENGINE MECHANICALPARTIAL ENGINE ASSY(1CD±FTV)
14±303
AVENSIS REPAIR MANUAL (RM1018E)
184.INSTALL AIR TUBE NO.1
(a)Install the new air hose No. 1 and new hose clamp as
shown in the illustration.
(b)Tighten the hose clamp as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c)Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
185.INSTALL INJECTOR DRIVER Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
186.CONNECT ENGINE WIRE Torque: 8.4 N
m (85 kgf
cm,74 in.
lbf)
187.INSTALL AIR TUBE NO.2
(a)Install the air hose and hose clamps as shown in the il- lustration.
(b)Tighten the hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm,53 ft
lbf)
(c)Install the 2 bolts and the air tube No.2 assy.
Torque: 25 N
m (255 kgf
cm,18 ft
lbf)
188.INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See page 16±51)
189. INSTALL ENGINE ROOM RELAY BLOCK NO.3 Torque: 5.3 N
m (54 kgf
cm, 46 in.
lbf)
190. INSTALL FUEL FILTER ASSY Torque: 18 N
m (178 kgf
cm, 13 ft
lbf)
http://vnx.su

141CF±01
A76700
Cylinder Head
Cover No. 2
Radiator Support
Upper
Radiator Support Upper
Radiator
Hose Inlet
Radiator Hose Outlet
Radiator Assy Clip
7.0 (71, 62 in.

lbf)
19 (194, 14)
Engine Under Cover LH
Engine Under Cover RH
Clip
Clip
N´m (kgf´cm, ft´lbf): Specified torque
Clip
Engine Under Cover No.1
19 (194, 14)
Retainer
Clip
Clip
Engine Room Cover Side
Radiator Suport Opening Cover
5.0 (51, 44)
Relay Block
Oil Cooler Inlet Tube No.1
Oil Cooler
Outlet Tube No.1
x2
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±19
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
http://vnx.su

A76724
A76714
A78461
1ZZ±FE
A78497
3ZZ±FE
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±29
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE RADIATOR ASSY
(a) Remove the 2 bolts and the relay block.
(b) Disconnect the connector and the 2 harness clamps.
(c) Remove the 2 bolts, the 2 radiator support upper and the
radiator.
21. REMOVE BATTERY
22. REMOVE BATTERY TRAY
23. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts, the battery carrier and the bracket.
24.REMOVE EFI FUEL PIPE CLAMP(See page 11±11)
25. DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11)
26. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator control cable.
27. DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a) Disconnect the union to connector tube hose.
28. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose from the heater core inlet tube.
29. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose from the heater core outlet tube\
.
30. DISCONNECT OIL COOLER INLET HOSE (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet hose from the automatic transaxle.
31. DISCONNECT OIL COOLER OUTLET HOSE (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet hose from the automatic transaxle.
http://vnx.su

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.
http://vnx.su

01±10
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E) Abbreviations Meaning
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RRSRigid Rear Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RRRear
RRSRear±Wheel Drive
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free±Tronic
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRCTraction Control System
TURBOTurbocharge
TWCThree±Way Catalyst
U/DUnderdrive
U/SUndersize
http://vnx.su