key TOYOTA AVENSIS 2003 Service Owner's Guide

SST
A09583
Inward
Angle Sensor
±
LUBRICATIONOIL PUMP ASSY(1CD±FTV)
17±29
AVENSIS REPAIR MANUAL (RM1018E)
47.INSTALL CRANKSHAFT TIMING PULLEY
(a)Align the keyway of the timing pulley with the key located
on the camshaft, slide the pulley into place.
(b)Using SST and a hammer, tap in the timing pulley with the angle sensor facing inward.
SST09223±46011
48.INSTALL TIMING BELT IDLER SUB±ASSY NO.2 Torque: 47 N
m (479 kgf
cm,35 ft
lbf)
49.SET NO. 1 CYLINDER TO TDC/COMPRESSION(See page 14±307) SST 09960±10010 (09962±01000, 09963±01000)
50.INSTALL TIMING BELT(See page 14±307)
51.CHECK VALVE TIMING(See page 14±307)
52.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
53.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
54.INSTALL TIMING BELT GUIDE(See page 14±307)
55.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
56.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
57.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
58. INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
59. INSTALL IDLER PULLEY SUB±ASSY
60.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
61. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
62.INSTALL INJECTOR DRIVER (See page 14±307)
63. INSTALL ENGINE COVER NO.1 Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
64. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
65.ADD ENGINE OIL(See page 17±30)
66. CHECK FOR ENGINE OIL LEAKS
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170FR±01
B08737
A30890
±
LUBRICATIONOIL PUMP ASSY(1ZZ±FE/3ZZ±FE)
17±3
AVENSIS REPAIR MANUAL (RM1018E)
OIL PUMP ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.DRAIN ENGINE OIL
(a)Remove the oil pan drain plug and drain engine oil.
2.REMOVAL & INSTALLATION CHAIN SUB±ASSY (See page 14±49)
3.REMOVE CHAIN VIBRATION DAMPER NO.1
(a)Remove the 2 bolts and the chain vibration damper No. 1.
4.REMOVE OIL PUMP ASSY
(a)Remove the 5 bolts.
(b)Remove the oil pump assy and the gasket.
5.INSTALL OIL PUMP ASSY
(a)Place a new gasket on the cylinder block.
(b)Align the keyway of the oil pump drive rotor with the rect-angular portion of the crankshaft and slide the oil pump
into place.
(c)Install the oil pump with the 5 bolts. Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
6.INSTALL CHAIN VIBRATION DAMPER NO.1
(a)Install the chain vibration damper No. 1 with 2 bolts. Torque: 9.0 N
m (92 kgf
cm,8.0 in.
lbf)
7.INSTALL OIL PAN DRAIN PLUG
(a)Clean and install the oil pan drain plug with a new gasket.
Torque: 37 N
m (377 kgf
cm,27 ft
lbf)
8.ADD ENGINE OIL (See page 17±4)
9.ADD ENGINE COOLANT (See page 16±7)
10. CHECK FOR ENGINE OIL LEAKS
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
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4100Y±05
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)
41±1
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.

: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANS\
AXLE Repair
Manual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E\
)
SymptomSuspect AreaSee page
Noise
6. Oil (Level low)
7. Oil (Wrong) C50/C250
E354/E357
8. Gear (Worn or damaged)
9. Bearing (Worn or damaged)41±2
41±3
41±5



Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged) C50/ C250 E354/E357
4. O±Ring (Worn or damaged)41±2


41±3
41±5

Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)41±7




Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)







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F44782
Transponder Key Amplifier

Tapered±Head Bolt
Steering Column Clamp Upper
Ignition or Starter Switch Assy
Un±lock Warning
Switch Assy
Steering Column Upper W/Switch Bracket Assy
Ignition Switch Lock Cylinder Assy
Non±reusable part


Steering Column Assy
50±6
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
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F44780
Transponder Key Amplifier AssyTapered±head Bolt
Ignition or Starter Switch Assy
Steering Column Assy


Non±reusable part

Steering Column Clamp Upper
Un±lock Warning
Switch Assy Steering Column Upper w/ Switch Bracket Assy
Ignition Switch Lock Cylinder Assy
50±8
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
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F44793Matchmarks
F44794
Screw
Extractor
F44795
SST
F44796
F44797
50±14
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
33. REMOVE STEERING INTERMEDIATE SHAFT ASSY NO.2 (LHD STEERING POSITION TYPE)
(a) Place matchmarks on the steering intermediate shaft
assy No. 2 and steering main shaft.
(b) Remove the bolt and steering intermediate shaft assy No. 2.
(c) W/VSC:
Remove the steering sensor (See page 32±65).
34. REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Using a centering punch, mark the center of the 2 ta- pered±head bolts.
(b) Using a 3 ± 4 mm (0.12 ± 0.16 in.)drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts and steering column upper with switch bracket assy.
NOTICE:
Do not give the strong force to the motor part.
35. INSPECT STEERING COLUMN ASSY (ELECTRIC POWER STEERING)
(a) Using SST and a torque wrench, check the rotating torque.
SST 09616±00011
Rotating torque (1 turn for 2 sec.):
0.4 ± 1.1 N
m (4 ± 11 kgf
cm, 3.5 ± 9.5 in.
lbf)
36. REMOVE TRANSPONDER KEY AMPLIFIER
(a) Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver.
(b) Pull the transponder key amplifier toward the rear of the
vehicle with the claw open.
NOTICE:
Take care not to use excessive force to prevent the case
from being damaged.
37. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY
(a) Place the ignition switch lock cylinder assy at the ACC position.
(b) Push down the stop pin with a screwdriver, and pull out the cylinder assy.
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F44798
F44799
F44793Matchmarks
±
STEERING COLUMN STEERING COLUMN ASSY
50±15
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE UN±LOCK WARNING SWITCH ASSY
(a) Slide the unlock warning switch assy out of the steering column upper br\
acket.
39. REMOVE IGNITION OR STARTER SWITCH ASSY
(a) Remove the 2 screws and ignition or starter switch assy.
40. INSTALL IGNITION OR STARTER SWITCH ASSY
(a) Install the ignition or starter switch assy to the steering column upper w/swit\
ch bracket assy with the
2 screws.
41. INSTALL UN±LOCK WARNING SWITCH ASSY
(a) Install the un±lock warning switch assy.
(b) Connect the un±lock warning switch assy connector to the ignition or \
starter switch assy.
42. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
(a) Make sure of the ignition switch lock cylinder assy at the ACC position.\
(b) Install the ignition switch lock cylinder assy.
43. INSPECT STEERING LOCK OPERATION
(a) Check that the steering lock mechanism is activated when removing the ke\
y.
(b) Check that the steering lock mechanism is deactivated when inserting the\
key and turning it to ACC position.
44. INSTALL TRANSPONDER KEY AMPLIFIER
(a) Align the transponder key amplifier with the installationposition of the upper bracket with the amplifier inclined.
(b) Push the transponder key amplifier up and connect it to the upper bracket.
NOTICE:
Take care not to push the amplifier up with excessive force
to prevent it from being damaged.
45. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
(a) Temporarily install the steering column upper with switch bracket assy and steering column upper clamp with 2 new
tapered±head bolts.
(b) Tighten the 2 tapared±head bolts until the bolt heads break off.
46. INSTALL STEERING SLIDING YOKE SUB±ASSY (RHD STEERING POSITION TYPE)
(a) W/VSC:
Install the steering sensor (See page 32±65).
(b) Align matchmarks on the steering sliding yoke and steer- ing main shaft.
(c) Oil Pressure Power Steering
(1) Install the steering sliding yoke with the bolt.
Torque: 28 N
m (286 kgf
cm, 21 ft
lbf)
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B16200
B16200
B16200
E64835
E68131
±
LIGHTING LIGHTING SYSTEM
65±11
AVENSIS REPAIR MANUAL (RM1018E)
8. TAIL LAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
9. FOG LAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
10. REAR FOG LAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
11. RUNNING LIGHT RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
12. TRANSPONDER KEY AMPLIFIER
(a) Inspect key cylinder operation. (1) Connect the battery positive (+) lead to the terminal
2 and the battery negative (±) lead to the terminal
6, and check that the indicator light comes on.
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B58556
Front Door
Courtesy Lamp
SwitchPushed
Free
Body Ground
70±12
±
WINDSHIELD/WINDOWGLASS/MIRROR POWER WINDOW CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(a) Disconnect the DA, DB, DC, DH and DN J/B connectors.
(b) Check the voltage and resistance between each terminal of the wire harness si\
de connectors and the body ground.
Standard:
Tester ConnectionConditionSpecified Condition
DA±8 ± Body groundNo key inserted in ignition key cylinder
Ye s10 k
or higher
Below 1

DA±9 ± Body groundConstantBelow 1

B±13 ± Body groundDriver side door CLOSED
OPEN10 k
or higher
Below 1

DC±9 ± Body groundPassenger side door CLOSED
OPEN10 k
or higher
Below 1

DH±5 ± Body groundIgnition switch ON
Others10 to 14 V
0 V
DN±1 ± Body groundConstant10 to 14 V
If the result is not as specified, there may be a malfunction on the wir\
e harness side or the J/B assy (integra-
tion relay) may have a malfunction.
(c) Reconnect the DA, DB, DC, DH and DN J/B connectors.
(d) Check the voltage of terminal 5 of the DH connector.
Standard:
Tester ConnectionConditionSpecified Condition
DH±5 ± Body groundIgnition switch ON
Others10 to 14 V
0 V
If the result is not as specified, there may be a malfunction on the wir\
e harness side or the J/B assy (integra-
tion relay) may have a malfunction.
9. INSPECT FRONT DOOR COURTESY LAMP SWITCHASSY
(a) Remove the courtesy lamp switch.
(b) Check the switch resistance. Standard:
Tester ConnectionSwitch PositionSpecified Condition
1 Body groundSwitch pushed10 k
or higher1 ± Body groundSwitch freeBelow 1

If the result is not as specified, replace the switch assy.
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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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