relay TOYOTA AVENSIS 2003 Service Workshop Manual

320VY±01
F45949
±
BRAKE BRAKE ACTUATOR ASSY (W/O VSC)
32±53
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/O VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake \
pedal cannot be de- pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously\
. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously\
. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
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320VU±01
F45162
Vacuum HoseClipBrake Vacuum
Check Valve
Check Valve
Grommet Clevis Pin
Clip
Wave Washer
13 (130, 9)
Engine Room Relay Block
Way
Clutch Reservoir Tube M/T Transaxle:
Front Brake
Tube No.5
15 (155, 11) *1
29 (296, 21) *2
Brake Fluid Level
Switch Connector

Brake Booster Gasket
20 (204, 15)
20 (204, 15)
Brake Master
Cylinder Sub±assy

Brake Booster Assy
Brake Master
Cylinder clevis
15 (155, 11)
Fuel Filter Assy
Diesel Engine Type:
Heater Assy
w/ Cold Area:
Air Cleaner Assembly
With Hose
Clutch Tube M/T Transaxle:Gasoline Engine Type:
15 (155, 11)
*1
w/ ABS:
*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
5.4 (55, 48 in.
lbf)
Charcoal Canister
Assy
32±18
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS
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320W7±01
F40019
F42620
±
BRAKE BRAKE BOOSTER ASSY (LHD)
32±19
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
3. SEPARATE ENGINE ROOM RELAY BLOCK
4. REMOVE CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
5.REMOVE FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
6.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
7.REMOVE HEATER ASSY (W/ COLD AREA) (See page 55±100)
8. REMOVE FRONT WHEEL LH
9. DISCONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, disconnect the brake line fromthe flexible hose of the front brake LH.
SST 09023±00100
10. REMOVE BRAKE BOOSTER ASSY
(a) Disconnect the vacuum hose from the brake booster assy.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts.
(d) Pull out the brake booster assy.
11. REMOVE BRAKE BOOSTER GASKET
(a) Pull out the brake booster gasket from the brake booster assy.
12. REMOVE CHECK VALVE
(a) Remove the check valve and grommet from the brake booster assy.
13. INSTALL CHECK VALVE
(a) Install the check valve and grommet to the brake booster assy.
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.
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F42620
F40019
32±20
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Install the clevis pin and clip to the brake master cylinder clevis.
(c) Connect the vacuum hose to the brake booster assy.
16. CONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, connect the brake tube to the flexible hose.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
17. INSTALL FRONT WHEEL LH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18.INSTALL HEATER ASSY (W/ COLD AREA) (See page 55±100)
19.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
20. INSTALL CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
21.INSTALL FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
22. CONNECT ENGINE ROOM RELAY BLOCK
23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
24.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
25.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
26.BLEED BRAKE LINE (See page 32±4)
27.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
28.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
29.CHECK PEDAL FREE PLAY (See page 32±6)
30.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
31. CHECK FUEL LEAK
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
33. CHECK BRAKE FLUID LEAKAGE
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320W5±01
G24285
LHD Steering Position Type:Charcoal Canister Assy
Brake Fluid Level
Switch Connector Clutch Reservoir
Tube M/T Transaxle:Brake Booster Assy
Clip
Way
20 (204, 15)
15 (155, 11)
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Brake Master
Cylinder Sub±assy
20 (204, 15)
Engin Room Relay Block
RHD Steering Position Type: Air Cleaner Cap Sub±assy
Brake Fluid Level
Switch Connector Brake Master
Cylinder Sub±assy
Clip
Accelerator Control
Cable Support
20 (204, 15)
*1
w/ ABS:*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Clutch Reservoir
Tube M/T Transaxle:
Brake Booster Assy
5.4 (55, 48 in.
lbf)
Fuel Filter Assy Diesel Engin Type:
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS
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320W6±01
G24218
G24217
F45393
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2. REMOVE ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
3. REMOVE AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
4. REMOVE CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
5. REMOVE FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
(a) Diesal engine type:
Remove the fuel filter assy with the 3 bolts.
6. REMOVE BRAKE MASTER CYLINDER SUB±ASSY(LHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle: Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Using SST, disconnect the 2 brake lines from the way. SST 09023±00100
(f) Remove the 2 nuts, and pull out the way and brake master cylinder sub±assy.
(g) Remove the O±ring from the brake master cylinder sub±
assy.
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G24225
32±16
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(c) w/o VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(d) w/ VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±38400
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
(e) M/T transaxle: Slide the clip and connect the clutch reservoir tube.
(f) Connect the brake fluid level switch connector.
12. INSTALL CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
13. INSTALL ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
14. INSTALL AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
15. INSTALL FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
16.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
17.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
18.BLEED BRAKE LINE (See page 32±4)
19.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
20.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
21. CHECK BRAKE FLUID LEAKAGE
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550RQ±02
55±6
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Whole functions of the A/C system does not operate.
4. ECU±B fuse
5. A/C amplifier assy
6. Wire harness or connector±
55±3 ±
Air Flow Control : No blower operation
1. Blower resistor
2. Heater relay
3. Blower w/ fan motor sub±assy
4. A/C amplifier assy
5. Wire harness or connector55±7
55±7
55±7
55±3±
Air Flow Control : No blower control
1. Blower w/fan motor sub±assy
2. Blower resistor
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3
±
Air Flow Control : Insufficient air out
1. Blower w/fan motor sub±assy
2. Blower resistor
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3±
Temperature Control : No cool air comes out
1. Volume of refrigerant
2. Drive belt tension
3. Refrigerant pressure
4. Cooler compressor assy
5. Pressure sensor
6. Condenser fan
7. Air mix damper servo sub±assy
8. A/C amplifier assy
9. Wire harness or connector55±24
55±46
55±2455±7
55±3 ±
55±7
55±3 ±
Temperature Control : No warm air comes out
1. Engine coolant volume
2. Cooler thermistor No.1
3. Air mix damper servo sub±assy
4. A/C amplifier assy
5. Heater radiator unit sub±assy
6. Wire harness or connector55±7
55±3
55±7
55±3±
±
Temperature Control : Output air is warmer or cooler than the set
temperature or response is slow.1. A/C amplifier assy
2. Air mix damper servo sub±assy
3. Air mix level55±3
55±7
±
Temperature Control : No temperature control
1. A/C amplifier assy
2. Air mix damper servo sub±assy
3. Air mix level55±3
55±7±
No air inlet control
1. Recirculation damper servo sub±assy
2. A/C amplifier assy
3. Wire harness or connector55±7
55±3±
No air outlet control
1. A/C amplifier assy
2. Mode damper servo sub±assy
3. Mode lever55±3
55±7±
Engine idle up does not occur, or is continuous
1. Idle up switch
2. Cooler compressor assy
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3±
Brightness does not changes when rheostat volume or light con-
trol switch it turned.1. Illumination light system
2. A/C amplifier assy
3. Wire harness or connector±
55±3 ±
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E32993
55±12
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
8. INSPECT HEATER RELAY (M ANUAL AIR
CONDITIONING)
Terminal No.Specified condition
No continuity
3±5Less than 1

(When battery voltage applied to terminals 1 and 2.)
Less than 1

3±4No continuity
(When battery voltage applied to terminals 1 and 2.)
1±2Constant continuity
If continuity is not as specified, replace the rear cooler relay.
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550ZE±01
±
HEATER & AIR CONDITIONER ELECTRICAL TYPE POWER HEATER SYSTEM
55±13
AVENSIS REPAIR MANUAL (RM1018E)
ELECTRICAL TYPE POWER HEATER SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
PTC heater does not operate, when perform in these conditions:

Engine coolant temp.: 70 C (158 F) or below

Engine speed: 650 rpm or above

Temperature control selector: MAX. HOT

Ambient temperature: Below 10 C (50 F)
1. HTR1 Fuse
2. HTR2 Fuse
3. HTR1 relay
4. HTR2 relay
5. PTC heater
6. ECM
7. Wire harness±
±
±
±
55±14
±
±
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