Seat TOYOTA AVENSIS 2003 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 14 of 2234
NEW MODEL OUTLINE
\b
\b
\b
Power Lumber Support
Power Seat
Cushion Front Tilt
Power Seat
Seat Slide
Power Seat Manual Seat
Seat Reclining
Power SeatVertical Lifter
Power Seat Manual Seat
Manual Seat
MO-14
Seat
The seat features a high-quality
finish with an elegant stitch.
Leather seats are available as an
option for MID TECHNICAL and
MID ELEGANT grade with the
1AZ-FSE or 1CD-FTV engine
models.
Front Seat
Power seats are available as a set option with leather seats.
The adjustment lever of manual seats now features a ratchet mechanism fo\
r ease of
operation.
A seat heater is available as an option for Europe LHD models.
Front Seat Function
ItemManual Seat Power SeatItemDriver'sPassenger's Driver'sPassenger's
Seat Slide 240 mm: 15 mm x 16-Steps 240 mm: Step Less
Seat Reclining 48 : Step Less (Lever 1 operation: Max. 1 )4 8: Step Less
Vertical Lifter 45 mm: Step Less (Lever 1
operation: Max. 2.5 mm) Ð
50 mm: Step Less Ð
Cushion Front Tilt ÐÐ34 mm: Step Less Ð
Power Lumber Support ÐÐStandard Ð
Headrest Vertical Adjuster 60 mm: 15 mm x 4-Steps
Headrest Swing Adjuster 18.5 : Standard (MID TECHNICAL and MID ELEGANT grade for Europe and General Countries)
Seat Heater Option: LHD for Europe
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Page 15 of 2234
MO
NEW MODEL OUTLINE
\b\b\b
Fixed Seat60:40 Separate Seat Back 60:40 Separate Seat
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\b
Sedan Model Liftback and Wagon Model
CRS Tether Anchor Bracket
CRS ISO-FIX Bar CRS Tether Anchor Bracket
CRS ISO-FIX Bar
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\b
Sedan Model Liftback ModelGrocery Bag
Hook (Both Side)
Tie-down
Hook
Auxiliary Box
Tie-down
HookTool Box
Tie-down Hook Auxiliary Box Grocery Bag Hook (Both Side)
Tie-down
Hook
Tool Box Tie-down
HookAuxiliary
Box
MO-15
Rear Seat
ENTRY grade sedans feature a fixed seat; other models feature seats with a 6\
0:40 separate
seat back.
Liftback and wagon models feature a 60:40 separate seat.
CRS (Child Restraint System) ISO-FIX bar and CRS tether anchor bracket\
for securing child
seats have been provided on all the vehicle.
Luggage
4-Door Sedan and 5-Door Liftback
The luggage room features an auxiliary box, grocery bag hook, and tie-do\
wn hook for ease of
use.
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Page 16 of 2234
MO
NEW MODEL OUTLINE
\b\b\b
Fixed Seat60:40 Separate Seat Back 60:40 Separate Seat
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\b
Sedan Model Liftback and Wagon Model
CRS Tether Anchor Bracket
CRS ISO-FIX Bar CRS Tether Anchor Bracket
CRS ISO-FIX Bar
\b
\b
Sedan Model Liftback ModelGrocery Bag
Hook (Both Side)
Tie-down
Hook
Auxiliary Box
Tie-down
HookTool Box
Tie-down Hook Auxiliary Box Grocery Bag Hook (Both Side)
Tie-down
Hook
Tool Box Tie-down
HookAuxiliary
Box
MO-15
Rear Seat
ENTRY grade sedans feature a fixed seat; other models feature seats with a 6\
0:40 separate
seat back.
Liftback and wagon models feature a 60:40 separate seat.
CRS (Child Restraint System) ISO-FIX bar and CRS tether anchor bracket\
for securing child
seats have been provided on all the vehicle.
Luggage
4-Door Sedan and 5-Door Liftback
The luggage room features an auxiliary box, grocery bag hook, and tie-do\
wn hook for ease of
use.
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Page 28 of 2234
NEW MODEL OUTLINE
SRS Airbag
SRS Knee Airbag
SRS Curtain Shield Airbag SRS Side Airbag
MO-26
SAFETY
SRS (Supplemental Restraint System) Airbag System
A newly developed SRS knee airbag is standard equipment for the driver's seat on the new
Avensis.
The SRS knee airbag is positioned in the lower part of the instrument pa\
nel on the driver's side
to receive the impact of the driver's lower body when he or she shifts forward in the event of
a frontal collision, contributing to prevention of secondary impact to t\
he lower body.
Dual-stage SRS airbags are standard equipment for the driver and front p\
assenger seats. In
the event of a severe frontal collision, the airbags function with the s\
eat belts to help reduce
the impact on the driver's and front passenger's head and chest. The seat position sensor is
adopted only for the driver's seat to help the driver side SRS airbag deploy at the right moment.
SRS side airbags (driver / front passenger seats) which help ease side\
impacts, are standard
equipment.
SRS curtain shield airbags (front/rear seats) that help ease side impa\
cts are standard
equipment for all models except 1AZ-FE engine models. They are available as an op\
tion for
1AZ-FE engine models.
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Page 30 of 2234
NEW MODEL OUTLINEMO-28
EQUIPMENT LIST
: Standard OP: Option
EuropeGeneral
ENTRYMID
TECHNICALMID
ELEGANTGeneral
Countries
Exterior
Rear SpoilerWagonÐ
Side Protection MouldingOPOPOPOP
WindshieldGreenÐ
Front SideGreen
GlassRear Side & BackGreenGlassRear Side & BackWagonPrivacyOPOPOPÐ
Rear QuarterWagonGreenÐRear QuarterWagonPrivacyOPOPOPÐ
Chassis
195/65 R153ZZ-FE & 1ZZ-FE & 1AZ-FE
205/55 R161AZ-FSE & 1CD-FTVÐ
Tire205/55 R163ZZ-FE & 1ZZ-FE & 1AZ-FEOPOPOPOP
215/45 R171AZ-FEÐOPOPÐ215/45 R171AZ-FSEÐOPOPÐ
15 x 6J Steel3ZZ-FE & 1ZZ-FE & 1AZ-FE
16x61/2J Steel1AZ-FSE & 1CD-FTVÐ16 x 6 1/2 J Steel3ZZ-FE & 1ZZ-FE & 1AZ-FEOPOPOPOP
Disc Wheel16 x 6 1 / 2 JJ AluminumOPOPOPOP
16 x 6 1 / 2 JJ Light Weight AluminumOPOPOPOP
17 x 7JJ Aluminum1AZ-FEÐOPOPÐ17 x 7JJ Aluminum1AZ-FSEÐOPOPÐ
ABS (Anti-lock Brake System) with EBD (Electronic Brake force Distrib\
ution)
VSC (Vehicle Stability Control) & Brake1AZ-FSEÐ(y)Assist & TRC (Traction Control)1CD-FTVOPOPOPÐ
Wheel4-Spoke UrethaneÐÐWheel4-Spoke LeatherÐÐ
SteeringColumnManual Tilt & TelescopicSteeringEPS*13ZZ-FE & 1ZZ-FEÐ
Hydraulic Type Power
Steering1AZ-FSE & 1CD-FTV & 1AZ-FE
Body
CoverFabricCoverLeather1AZ-FSE & 1CD-FTVÐOPOPÐ
FrontManual
SeatFrontPower1AZ-FSE & 1CD-FTVÐOPOPÐ
FixSedanÐÐÐ
Rear60:40 FoldingSedanÐ
60:40 Double FoldingLiftback & WagonÐ
SeatBelt
Front3-Point ELR*2 Electrical Sensing Type Pretensioner
& Force Limiter
BeltRear3-Point ELR*2 & ALR*3
CRS (Child Restraint System) Anchor System (Rear Outside Seat Only)
*1: Electoronic Power Steering
*2: Emergency Locking Retractor
*3: Automatic Locking Retractor
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Page 71 of 2234
010LF±01
D25016
±
INTRODUCTION REPAIR INSTRUCTION
01±5
AVENSIS REPAIR MANUAL (RM1018E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1LooksAlways wear a clean uniform.
Hat and safety shoes must be worn.
2Vehicle protectionSet a grill cover, fender cover, seat cover and floor mat before starting operation.
3Safe operation
When working with 2 or more persons, be sure to check the safety of one \
another.
When working with the engine running, pay attention to providing ventila\
tion for exhaust fumes in the work-
shop.
When working with high±temperatures, rotating, moving or vibrating pa\
rts, be careful not to burn or injure
yourself.
When jacking up the vehicle, be sure to support the specified location w\
ith a safety stand.
When lifting up the vehicle, use safety equipment.
4Preparation of tools and
measuring gaugeBefore starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations
Diagnose with a thorough understanding of the trouble condition and perf\
orm effective operation.
Before removing the parts, check the general condition of the assembly, and for deformation and damage.
When the structure is complicated, take a notes or make matchmarks as no\
t to make mistakes that affect the
function of the parts.
Clean and wash the removed parts if necessary and assemble them after a \
thorough check.
6Removed parts
Place the removed parts in the correct order to avoid mixing them up or \
making them dirty.
As for non±reusable parts such as gaskets, O±rings, and self±lo\
cking nuts, replace them with new ones
following the instructions in this manual.
Organize the parts that were replaced in a box and show them to the cust\
omer.
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Page 75 of 2234
L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
±
INTRODUCTIONREPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench Nmkgfcmftlbf
TTorque Nmkgfcmftlbf
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE (1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.
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Page 76 of 2234
D30401
Mark
01±10
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Even in the case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly and seat belt pretensioner should be in\
spected
(See pages 60±19, 60±19 and 61±9).
(4)Never use the SRS related parts from another vehicle. When replacing the part\
s, replace them with new parts.
(5)Before repairs, remove the airbag sensor if there is a possibility of sh\
ock during repairs.
(6)Never disassemble and repair the center airbag sensor assembly, side airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly,
curtain shield airbag assembly or seat belt pretensioner.
(7)If the center airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly have been dropped, or if the\
re are cracks,
dents or other defects in the case, bracket or connector, replace them with new ones.
(8)Do not directly expose the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly or the seat belt pretensioner
to hot air or flames.
(9)Use a volt/ohmmeter with high impedance (10 k/V minimum) for troubleshooting electrical cir-
cuits.
(10)Information labels are attached to the SRS components. Follow the instru\
ctions on the notices.
(11)After work on the supplemental restraint system is completed, check the SRS w\
arning light (See page 05±1184)
(b)SPIRAL CABLE (in Combination Switch)(1)The steering wheel must be fitted correctly to thesteering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
troubles may occur. Refer to page 60±26 of this
manual concerning the correct installation of the
steering wheel.
(c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it sho\
uld be placed withthe top of the pad surface facing upward. Placing it with the pad surface facing downward may
lead to a serious accident if the airbag deploys for some reasons. Also, do \
not place anything
on top of the horn button.
(2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
(3) Grease should not be applied to the horn button assembly, and the pad should not be cleaned with any type of detergent.
(4) Store the horn button assembly where the ambient temperature remains below 93 C (200 F),
without high humidity and away from electrical noise.
(5) When using electric welding, disconnect the airbag connector (4 yellow pins\
) under the steering column near the combination switch connector before starting work.
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Page 78 of 2234
Z13951
Example:
D26612
Example:CORRECT WRONG
B01546
Example:
01±12
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(e)FRONT SEAT AIRBAG ASSEMBLY (1)Always store a removed or new front seat airbag assembly with the airbag infla\
ting direction fac-
ing upward.
Placing the airbag assembly with the airbag inflation direction facing d\
ownward could cause a
serious accident if the airbag inflates.
(2)Never measure the resistance of the airbag squib (This may cause the ai\
rbag to inflate, which
is very dangerous.).
(3)Grease should not be applied to the front seat airbag assembly and the airbag d\
oor should not be cleaned with detergents of any kind.
(4)Store the airbag assembly where the ambient temperature remains below 93C (200 F), without
high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the airbag connector (2 yello\
w pins) installed on the assembly before starting work.
(6)When disposing of a vehicle or the side airbag assembly alone, the airbag sh\
ould be inflated us- ing an SST before disposal (See page 60±47).
Perform the operation in a safe place away from electrical noise.
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Page 80 of 2234
D26602
Example:CORRECT WRONG
Clear Plastic Bag
D26603
Example:
01±14
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind.
(4)Store the airbag assembly where the ambient temperature remains below 93C (200 F), without
high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the airbag connector (4 yellow pins) from th\
e instru- ment panel before starting work.
(6)When disposing of a vehicle or the curtain shield airbag assembly alone, the airbag should be
deployed using SST before the disposal (See page 60±41). Perform operation in a safe place
away from electrical noise.
(h)SEAT BELT PRETENSIONER (1)Never measure the resistance of the seat belt pretensioner (This may cause t\
he seat belt preten-sioner to activate, which is very dangerous.).
(2)Never disassemble the seat belt pretensioner.
(3)Never install the seat belt pretensioner in another vehicle.
(4)Store the seat belt pretensioner where the ambient temperature remains b\
elow 80C (176F)
without high humidity and away from electrical noise.
(5)When using electric welding, first disconnect the connector (2 yellow pins) before starting work.
(6)When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensi\
oner should
be activated before disposal (See page 61±9). Perform the operation in a safe place away from
electrical noise.
(7) The seat belt pretensioner is hot after being activation, so allow some \
time for it to cool down sufficiently before disposal. Never apply water to cool down the seat be\
lt pretensioner.
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