lock TOYOTA AVENSIS 2003 Service Workshop Manual

031FW±01
03±44
±
SERVICE SPECIFICATIONS PARKING BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Wheel nut1031,05076
Parking brake lock nut5.05144 in.
lbf
Parking brake lever sub±assy x Body131279
Front floor heat insulator No.2 x Body5.55649 in.
lbf
Front floor heat insulator No.1 x Body5.55649 in.
lbf
Exhaust pipe installation bolt4344032
Front floor panel brace x Body3030221
Fuel tank protector No.1 x Body5.55649 in.
lbf
Parking brake cable assy No.3 x Fram5.05144 in.
lbf
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030G7±04
03±60
±
SERVICE SPECIFICATIONS POWER STEERING
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part tightenedN
mkgf
cmft
lbf
VANE PUMP ASSY (AZ Series)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Power steering oil pressure switch2121415
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy x Pump bracket rear4444932
Vane pump assy set bolt26 (37)264 (377)19 (27)
Pressure feed tube assy x Vane pump assy5252538
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
VANE PUMP ASSY (1CD±FTV)
Vane pump housing sub±assy rear x Vane pump housing sub±assy front2222416
Pressure port union sub±assy6970451
Power steering suction port union set bolt121229
Vane pump assy set bolt Bolt A:
Bolt B:72
39734
39853
29
Pressure feed tube assy x Vane pump assy41 (44.1)414 (450)30 (33)
Pressure feed tube assy clamp set bolt8.08271 in.
lbf
STEERING GEAR ASSY
Engine hanger set bolt3838728
Steering rack x Steering rack end sub±assy60 (83.5)616 (851)45 (62)
Tie rod end sub±assy lock nut7475054
Steering gear assy set bolt4950036
Steering intermediate shaft x Steering pinion shaft3536026
RACK & PINION POWER STEERING GEAR ASSY
Engine hanger set bolt AZ Series:
1CD±FTV:38
37390
37528
27
Tie rod end sub±assy lock nut7475054
Rack & pinion power steering gear assy set bolt4950036
Steering intermediate shaft x Control valve pinion shaft3536026
Front suspension crossmember sub±assy x Frame11 31,35698
Crossmember bracket x Frame Bolt A:
Bolt B:11 3
801,356 81698
59
Crossmember x Engine mounting insulator RR5253038
Center member x Frame4545933
Center member x Engine mounting insulator FR5253038
Front suspension arm sub±assy lower No.1 x Lower ball joint8990866
Front stabilizer link assy set nut7475555
Pressure feed tube assy x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Steering gear outlet return tube x Rack & pinion steering gear assy41 (44.1)414 (450)30 (33)
Outlet return tube clamp set bolt (LHD)8.08271 in.
lbf
Tie rod end sub±assy x Steering knuckle4950036
Steering intermediate shaft assy No.2 set bolts3536026
Front wheel hub nut1031,05076
( ): For use without SST(s)
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031HN±01
±
SERVICE SPECIFICATIONS SEAT
03±71
AVENSIS REPAIR MANUAL (RM1018E)
SEAT
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
FRONT SEAT
Seat Inner belt assy x Seat adjuster assy4242831
Seatback cover bracket x Seat adjuster assy (w/ Side airbag)6.06153 in.
lbf
Seat assy x Body3737527
Seat position airbag sensor x Seat adjuster assy8.08271 in.
lbf
Power seat motor assy (Reclining) x Seat adjuster assy4.54640 in.
lbf
Power seat motor assy (Slide) x Seat adjuster assy Bolt
Nut4.0
3.541
3635 in.
lbf
31 in.
lbf
Power seat motor assy (lifter) x Seat adjuster assy Bolt
Nut2.52525
25522 in.
lbf
18
Power seat motor assy (Front vertical) x Seat adjuster assy Bolt
Nut2.52525
25522 in.
lbf
18
Front seatback spring assy x Front seat adjuster2525518
REAR SEAT
Armrest assy x Seatback assy8.08271 in.
lbf
Seat belt assy outer center x Seatback frame4242831
Seat belt assy outer center x Body4242831
Seatback lock assy x Seatback frame3030622
Seatback hinge x Seatback frame1818513
Seatback hinge x Body1818513
Seatback hinge center x Body1818513
Seatback hinge center x Seatback frame1818513
Side seatback assy x Body1818513
Bench type seatback assy x Body1818513
Seat cushion frame x Body1818513
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031E7±03
±
SERVICE SPECIFICATIONS STARTING & CHARGING
03±33
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
1ZZ±FE/3ZZ±FE:
Part TightenedN
mkgf
cmft
lbf
Starter assy x Transaxle housing3737828
Starter wire x Starter assy9.81007
Generator assy x Transverse engine engine mounting bracket2525518
Generator assy x Cylinder block sub±assy5455140
Generator wire x Generator assy9.81007
Lead wire of field coil x Terminal C5.96052 in.
lbf
1AZ±FE/1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Wire harness clamp bracket x Starter assy8.48674 in.
lbf
Starter assy x Cylinder block sub±assy3738028
Starter wire x Starter assy9.81007
Battery carrier x Body131319
Battery clamp sub±assy x Body5.05144 in.
lbf
Battery clamp sub±assy x Battery clamp bolt3.63631 in.
lbf
Terminal x Battery5.45548 in.
lbf
Wire harness clamp bracket x Generator assy8.48674 in.
lbf
Generator assy x Cylinder block sub±assy Bolt A
Bolt B52
21530
21438
16
Generator wire x Generator assy9.81007
Lead wire of field coil x Terminal C5.96052 in.
lbf
1CD±FTV:
Part TightenedN
mkgf
cmft
lbf
Starter x Transaxle Bolt
Terminal 3037
9.8377
10027
7.2
Generator assy x Engine M8
M10
Alternator wire Wire harness31
47
9.8
5.0320
475
100
5123
347
44 in.
lbf
Glow plug assy x Cylinder head Glow plug
Nut12.32.2125229
19 in.
lbf
Engine cover No. 1 x Cylinder head cover sub±assy8.08271 in.
lbf
Engine cover No. 1 x Intake manifold8.08271 in.
lbf
Front wheel RH1031,05076
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VTA E2 VC
A35493
±
ENGINE CONTROL SYSTEM SFI SYSTEM (1AZ±FE)
10±21
AVENSIS REPAIR MANUAL (RM1018E)
(b) Adjust the throttle stop screw.
NOTICE:
The throttle stop screw adjusting is very, so adjust it only
when the adjusting is really needed.
(1) Loosen the locknut and loosen the screw until it de-taches the lever.
(2) Confirm that the throttle vale is fully closed.
(3) After the screw touches the lever, tighten it by 1/4
revolution additionally and tighten the lock nut.
(4) Seal the lock nut with yellow paint.
(5) Check that the throttle position sensor operates normally.
4. INSPECT THROTTLE POSITION SENSOR
(a) Resistance inspection. (1) Disconnect the throttle position sensor connector.
(2) Using an ohmmeter, measure the resistance be-tween terminals VC and E2.
Resistance: 2.5 to 5.0 k

(3) Check the change of resistance between terminals VTA and E2.
Change of resistance:
The resistance value increases in proportion to the
throttle lever opening value.
HINT:
Throttle valveResistance
Fully close0.2 to 5.7 k

Fully open2.0 to 10.2 k

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A77873
(a)
(c)
(b)
(d)
(h)
(i)
(g)
(g)
(f)
(e)
Air cleaner clamp
(c)
A77874
±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (1AZ±FE)
10±27
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE AIR CLEANER CAP SUB±ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV connector.
(c) Remove the 2 wire harness clamps.
(d) Disconnect the ventilation hose.
(e) Disconnect the fuel vapor feed hose No. 1.
(f) Disconnect the fuel vapor feed hose N0. 2.
(g) Remove the fuel vapor feed hose No. 2 from 2 clamps of
the air cleaner hose.
(h) Lock the hose clamp as shown in the illustration.
(i) Raise the air cleaner clamp up, slide it to the air cleaner cap.
(j) Remove the air cleaner cap together with air cleaner hose No. 1.
6. SEPARATE ACCELERATOR CONTROL CABLE ASSY
(a) Loosen the nut and separate the accelerator control cable.
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A77879
45

A77880
83.8 mm
(3.299 in.)
Rotation
Center of
Throttle Link
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(1AZ±FE)
10±29
AVENSIS REPAIR MANUAL (RM1018E)
11.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that throttle valve is fully closed.
(b)With the throttle position sensor rotated 45
counter-
clockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure
it with the 2 screws.
12.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 3 screws.
13.INSTALL FUEL VAPOR FEED HOSE NO.2
14.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the fuel pipe support with the 3 bolts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(c)Install the fuel tube to the fuel pipe support.
(d)Connect the water by±pass hose.
(e)Connect the water by±pass hose No. 2.
(f)Connect the ISC valve connector.
(g)Connect the throttle position sensor connector.
15.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Instal the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
16.INSTALL AIR CLEANER CAP SUB±ASSY
17.INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
18.ADD ENGINE COOLANT (See page 16±19)
19.CHECK FOR ENGINE COOLANT LEAKS (See page 16±13)
20. INSTALL ENGINE ROOM COVER SIDE
21. INSTALL RADIATOR SUPPORT OPENING COVER
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A78464
A78465
A78466
A78467
30
to 45

±
ENGINE CONTROL SYSTEM THROTTLE BODY ASSY (1ZZ±FE)
10±11
AVENSIS REPAIR MANUAL (RM1018E)
8. REMOVE ACCELERATOR CONTROL CABLE
BRACKET
(a) Remove the 2 bolts, and then remove the accelerator
control cable bracket.
9. REMOVE ISC VALVE
(a) Remove the 3 screws, and then remove the ISC valve.
(b) Remove the gasket from the throttle body.
10. REMOVE THROTTLE POSITION SENSOR
(a) Remove the 2 screws, and then remove the throttle posi- tion sensor.
11. INSTALL THROTTLE POSITION SENSOR
(a) Make sure that the throttle valve is fully closed.
(b) With the throttle position sensor rotated 30
to 45
coun-
terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c) Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
12. INSTALL ISC VALVE
(a) Install a new gasket to the throttle body.
(b) Install the ISC valve with the 3 screws. Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
13. INSTALL ACCELERATOR CONTROL CABLE BRACKET
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
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A78501
A78503
30
to 45

A78469
66.3 mm
(2.610 in.)
Rotation
Center of
Throttle Link
11

10±16
±
ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY(3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE THROTTLE POSITION SENSOR
(a)Remove the 2 screws, and then remove the throttle posi- tion sensor.
10.INSTALL THROTTLE POSITION SENSOR
(a)Make sure that the throttle valve is fully closed.
(b)With the throttle position sensor rotated 30
to 45
coun- terclockwise about the fully closed position of the throttle
valve, install the throttle position sensor to the throttle
body.
(c)Rotate the throttle position sensor clockwise and secure it with the 2 screws.
Torque: 2.0 N
m (20 kgf
cm, 18 in.
lbf)
11.INSTALL ISC VALVE
(a)Install a new gasket to the throttle body.
(b)Install the ISC valve with the 4 screws.
Torque: 3.7 N
m (38 kgf
cm, 33 in.
lbf)
12.INSTALL THROTTLE BODY ASSY
(a)Install a new gasket to the intake manifold.
(b)Install the throttle body and the accelerator control brack- et with the bolt and 2 nuts.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
13.INSTALL ACCELERATOR CONTROL CABLE ASSY
(a)Install the accelerator control cable as shown in the il- lustration.
Torque: 13 N
m (129 kgf
cm, 9 ft
lbf)
14.INSTALL AIR CLEANER CAP SUB±ASSY (See page 10±9)
15.INSTALL CYLINDER HEAD COVER NO.2 (See page 10±9)
16.ADD ENGINE COOLANT (See page 16±7)
17.CHECK FOR ENGINE COOLANT LEAKS (See page 16±1)
18. INSTALL ENGINE ROOM COVER SIDE
19. INSTALL RADIATOR SUPPORT OPENING COVER
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A81588
31
22
A63387
Retainer
Fuel Tube Connector
O±ring
Pipe
A77890
A77894
A78270
±
FUEL FUEL TANK ASSY (DIESEL)
11±107
AVENSIS REPAIR MANUAL (RM1018E)
16. DISCONNECT FUEL TANK MAIN TUBE SUB±ASSY
(a) Pinch the tab of the retainer to remove the lock claws and
pull down it as shown in the illustration.
(b) Pull out the fuel tank main tube.
NOTICE:

Check if there is any dirt or mud around the connector
before this operation and remove the dirt as neces-
sary.

Be careful of mud because the quick connector has
an O±ring which seals the pipe and the connector that
can be contaminated.

Do not use any tool in this operation.

Do not bend or twist the nylon tube. Protect the con-
nector by covering it with a vinyl or a plastic bag.

When the pipe and connector are stuck, push and pull
the connector to release. Pull out the connector from
the pipe carefully.
17. REMOVE FUEL TANK ASSY
(a) Set up a transmission jack under the fuel tank.
(b) Remove the 4 bolts and 2 fuel tank bands, and then re- move the fuel tank.
18. REMOVE FUEL TANK MAIN TUBE SUB±ASSY
(a) Unfasten the 5 claws, and remove the fuel tank return tube from the fuel tank.
19. REMOVE FUEL EVAPORATION TUBE SUB±ASSY NO.2
(a) Unfasten the claw, and remove the fuel evaporation tube
from the fuel tank.
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