brake light TOYOTA AVENSIS 2003 Service Repair Manual

NEW MODEL OUTLINEMO-28
EQUIPMENT LIST

: Standard OP: Option
EuropeGeneral
ENTRYMID
TECHNICALMID
ELEGANTGeneral
Countries
Exterior
Rear SpoilerWagon


Ð
Side Protection MouldingOPOPOPOP
WindshieldGreen


Ð
Front SideGreen




GlassRear Side & BackGreen



GlassRear Side & BackWagonPrivacyOPOPOPÐ
Rear QuarterWagonGreen


ÐRear QuarterWagonPrivacyOPOPOPÐ
Chassis
195/65 R153ZZ-FE & 1ZZ-FE & 1AZ-FE




205/55 R161AZ-FSE & 1CD-FTV


Ð
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-FTV


Ð16 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 Urethane
ÐÐ
Wheel4-Spoke LeatherÐ

Ð
SteeringColumnManual Tilt & Telescopic



SteeringEPS*13ZZ-FE & 1ZZ-FE


Ð
Hydraulic Type Power
Steering1AZ-FSE & 1CD-FTV & 1AZ-FE




Body
CoverFabric



CoverLeather1AZ-FSE & 1CD-FTVÐOPOPÐ
FrontManual




SeatFrontPower1AZ-FSE & 1CD-FTVÐOPOPÐ
FixSedan
ÐÐÐ
Rear60:40 FoldingSedanÐ



60:40 Double FoldingLiftback & Wagon


Ð
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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D25081
Spring Type Clamp
Clamp Track
D20025
CG
DLC3
TS
D30964
±
INTRODUCTION REPAIR INSTRUCTION
01±17
AVENSIS REPAIR MANUAL (RM1018E)
6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of the insert-
ing portion and the clamp position to restore it surely.
(b) Change a deformed or dented clamp for a new one.
(c) In case of reusing a hose, attach the clamp on the clamp track portion of the hose.
(d) For a spring type clamp, adjust it by adding force to the
arrow mark direction after the installation.
7. FOR VEHICLES EQUIPPED WITH MOBILE COMMU- NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on applicable components.
(c) Prevent the antenna feeder from getting entangled with the other wiring, and keep the antenna feeder separate
from other wiring as much as possible.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high±powered mobile communication system.
8. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) SYSTEM
(a) NOTICES WHEN USING 2±WHEEL DRUM TESTER
(1) When using a 2±wheel drum tester such as a speedometer tester, a combination tester ofspeedometer and brake, chassis dynamometer or else, always turn the TRC system off via the
TRC OFF switch before measurement.
NOTICE:
TRC system OFF condition can be confirmed by the indication, ºTRC OFF\
º, of the warning light in
the combination meter.
9. FOR VEHICLES EQUIPPED WITH VEHICLE SKIDCONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) When using a drum tester, be sure to start the en-gine with the ignition OFF, and connect SST to the
terminals TS and CG of the DLC3 before measure-
ment in order to prohibit the VSC operation.
SST 09843±18040
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030MU±02
±
SERVICE SPECIFICATIONS BRAKE
03±41
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) RHD:
LHD: M/T
A/T142.5 ± 152.5 mm (5.610 ± 6.004 in.)
148.1 ± 158.1 mm (5.831 ± 6.224 in.)
149.9 ± 159.9 mm (5.902 ± 6.295 in.)
Brake Pedal free play1 ± 6 mm (0.04 ± 0.24 in.)
Stop light switch clearance0.5 ± 2.6 mm (0.020 ± 0.102 in.)
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf)More than 60 mm (2.36 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front disc brake pad thickness Standard
Minimum12.5 mm (0.492 in.)
2.0 mm (0.079 in.)
Front brake disc thickness Standard
Minimum26.0 mm (1.024 in.)
24.0 mm (0.945 in.)
Front disc runout Maximum0.05 mm (0.0020 in.)
Rear disc brake pad thickness Standard
Minimum10.0 mm (0.394 in.)
2.0 mm (0.079 in.)
Rear disc thickness Standard
Minimum10.0 mm (0.394 in.)
8.0 mm (0.315 in.)
Rear disc runout Maximum0.05 mm (0.0020 in.)
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3201G±07
BR2238
GOOD NO GOOD2nd 3rd
1st
BR2237
G24221
Ventilation No Ventilation
±
BRAKE BRAKE BOOSTER ASSY (LHD)
32±17
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (LHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight. (2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check. (1) Depress the brake pedal several times with the igni-tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve. (1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
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320GN±02
BR2238
GOOD NO GOOD2nd 3rd
1st
BR2237
G24221
Ventilation No Ventilation
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±21
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (RHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight. (2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check. (1) Depress the brake pedal several times with the igni-tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve. (1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
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±
BRAKE STEERING SENSOR
32±67
AVENSIS REPAIR MANUAL (RM1018E)
20.CONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
21.INSPECT SRS WARNING LIGHT (See page 05±1184)
22.INSPECT ABS WARNING LIGHT AND VSC WARNING LIGHT (See page 05±756)
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710CM±02
±
INSTRUMENT PANEL/METERCOMBINATION METER
71±1
AVENSIS REPAIR MANUAL (RM1018E)
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Discharge warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Brake warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
ABS warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
SRS warning light does not come on.
1.Wire Harness or Connector
2.Airbag Sensor Assy
3.Combination Meter Assy±
05±1197 ±
Open Door warning light does not come on.
1.Wire Harness or Connector
2.Front Door Courtesy Light
3.Body ECU
4.Combination Meter Assy±
±
±
±
Fuel Level warning light does not come on.
1.Wire Harness or Connector
2.Fuel Sender Gauge
3.Combination Meter Assy±
±
±
Low Oil Pressure warning light does not come on.
1.Wire Harness or Connector
2.Low Oil Pressure Warning Switch
3.Combination Meter Assy±
±
±
Engine Oil Level warning light does not come on.
1.Wire Harness or Connector
2.Oil Level Sensor
3.Combination Meter Assy±
±
±
Belt warning light does not come on.
1.Wire Harness or Connector
2.Body ECU
3.Front Inner Belt Assy
4.Combination Meter Assy±
±
05±1522
±
VSC warning light does not come on.
1.Wire Harness or Connector
2.VSC Circuit
3.Combination Meter Assy±
05±752 ±
Indicator Lights:
SymptomSuspect AreaSee page
Shift indicator light do not come on.
1. Wire Harness or Connector
2. ECM
3. Neutral Start Switch Circuit
4. Combination Meter Assy±
±
±
±
Turn indicator light does not come on.
1. Wire Harness or Connector
2. Turn Signal and Hazard Warning System
3. Combination Meter Assy±
65±9 ±
Glow indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy±
±
±
TRC off indicator light does not come on.
1. Wire Harness or Connector
2. VSC Circuit
3. Combination Meter Assy±
05±752 ±
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IG
SPEED
BKL SW
(D±seat)
BKL SW
(P seat)
WRN LAMP
BUZZERON
OFF
15km/h
0
BELT ON
BELT OFF
LVL1
LVL2 BELT ON
BELT OFF
ON
OFF OFF
30s
90s30s90s
±
INSTRUMENT PANEL/METER COMBINATION METER
71±5
AVENSIS REPAIR MANUAL (RM1018E)
7. INSPECT SEAT BELT WARNING LIGHT & BUZZER
(a) Check the operation.
(1) Turn the ignition switch to ON and check that the warning light comes on.\
(2) Fasten the outer belt to the inner belt and check that the warning light\
goes out.
(3) Disconnect the connector from the buckle switch and ground the terminal \
on the wire harness
side connector.
(4) Turn the ignition switch to ON and check that the warning light comes on.\
8. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Inspect the circuit. (1) Disconnect the connector from the low oil pressure switch.
(2) Turn the ignition switch to ON.
(3) Ground the terminal of the wire harness side connector, then check the low oil pressure warninglight.
Low oil pressure warning light: Come on
9. INSPECT BRAKE WARNING LIGHT
(a) Inspect the parking brake warning light.
(1) Disconnect the connector from the parking brake switch and ground the terminal on the wire har-ness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
(b) Inspect the brake fluid level warning light.
(1) Disconnect the connector from the brake fluid level warning switch and c\
onnect the terminalson the wire harness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
10. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Inspect the continuity.
(1) Remove the reservoir tank cap and strainer.
(2) Disconnect the connector.
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[N]
[O] [P]
[Q] [R]
[S]
[T]
[U]
6 AVENSIS (EWD526E)
B HOW TO USE THIS MANUAL
Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW.
When the ignition SW is turned on, current flows from the GAUGE fuse to TERM\
INAL 8 of the light failure sensor, and also flows
through the rear lights warning light to TERMINAL 4 of the light failure sensor\
.
Stop Light Disconnection Warning
When the ignition SW is turned on and the brake pedal is pressed (Stop ligh\
t SW on), if the stop light circuit is open, the cur
rent
flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, \
so the light failure sensor detects the
disconnection and the warning circuit of the light failure sensor is activated.
As a result, the current flows from TERMINAL 4 of the light failure sens\
or to TERMINAL 11 to GROUND and turns the rear lights
warning light on. By pressing the brake pedal, the current flowing to TERMINAL \
8 of the light failure sensor keeps the warning
circuit on and holds the warning light on until the ignition SW is turne\
d off.
S6 Stop Light SW
2–1 : Closed with the brake pedal depressed
L4 Light Failure Sensor 1, 2, 7–Ground : Approx. 12 volts with the stop light SW on 4, 8–Ground : Approx. 12 volts with the ignition SW at ON position11 –Ground : Always continuity
: Parts Location
CodeSee PageCodeSee PageCodeSee Page
C734L436R737
H1736R637S635
: Relay Blocks
CodeSee PageRelay Blocks (Relay Block Location)
118R/B No.1 (Instrument Panel Brace LH)
: Junction Block and Wire Harness Connector
CodeSee PageJunction Block and Wire Harness (Connector Location)
IB20Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel)
3C22Instrument Panel Wire and J/B No.3 (Instrument Panel Brace LH)
: Connector Joining Wire Harness and Wire Harness
CodeSee PageJoining Wire Harness and Wire Harness (Connector Location)
IE142Floor Wire and Instrument Panel Wire (Left Kick Panel)
BV150Luggage Room Wire and Floor Wire (Luggage Room Left)
: Ground Points
CodeSee PageGround Points Location
BL50Under the Left Center Pillar
BO50Back Panel Center
: Splice Points
CodeSee PageWire Harness with Splice PointsCodeSee PageWire Harness with Splice Points
I544Cowl WireB1850Luggage Room Wire
System Outline
Service Hints
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8AVENSIS (EWD526E)
B HOW TO USE THIS MANUAL
The ground points circuit diagram shows the connections from all major p\
arts to the respective ground points. When
troubleshooting a faulty ground point, checking the system circuits which use a common \
ground may help you identify
the problem ground quickly. The relationship between ground points (
EA, IB and IC shown below) can also be
checked this way.
5
5
5
5
44 4
4
4
BA1 5 IB1
8 EA2
ID115
IC3 3
IA1
2
E 3
W–B W–B W–B
W–B
W–B
W–B
W–B
W–B
W–BW –B
W–B
W–BW –B
W–B
W–BW –BW –B
W–B
W–B W–B
W–B
W–B
W–B
W–B
W–BW –BW–B
W–B
BR
W–B
BR BR
W–B W–B
W–B
W–B
W–B
W–B
W–B
W–BW –B
W–B
W–B
W–B
W–B
W–BBR
W–B
BR
BR
BR
W–B (4A–GZE)
W–B
W–B I 2
I 2
B 5
I 5 I 5
I 5
B 5
B 5
B 5
I 5
I 5 I 3
I 3
E 3
E 3
E 3
E 2
E 4
E 5
E 4
E 5
E 6
E 4 E 4
B 4
EA
I 4
B 4
B 4
I 4 I 8
IB IC
4
4 3E
5
3E 6
3G
13
3F
3
3D
1
3B
7 W–B
W–B
W–B
W–B
W–B
W–B
W–B
W–B
W–BW–B
W–B
W–B
W–B
W–B
W–B I 6
I 6
I 2
3C 7
10 A A
A
A
A
A
Junction
Connector J 1
W–B
W–B
W–BW –B
BR
W–B
W–B
W–B
W–B
W–B
W–B
I GROUND POINT
FAN MAIN Relay
FAN MAIN Relay
A/C Relay No.2
A/C Relay No.3
Radiator Fan Motor
Headlight Cleaner Relay
Headlight LH
Headlight RH
Front Fog Light LH
Brake Fluid Level SW Front Fog Light RH
Front Turn Signal Light RH
Front Clearance Light RH
Front Turn Signal Light LH
Front Clearance Light LH
Door Lock Control SW
Door Courtesy SW RH
Door Lock Motor RH
Door Lock Control Relay
Blower Resistor
Idle–Up SW
A/C Amplifier
Radio and Player
HEATER Relay
Auto Antenna Motor A/C Control Assembly
Blower Motor
Blower SW
Parking Brake SW
Combination Meter
Combination SW
Cruise Control ECU
Remote Control Mirror SW
Turn Signal Flasher
Defogger SW
Unlock Warning SW
Power Window Master SW
Power Window Control
Relay
Door Courtesy SW LH
Door Lock Control SW
Door Lock Motor LH
Fuel Control SW
Woofer Speaker Amplifier
Combination Meter
Combination Meter
Fuel Sender
Cigarette Lighter
O/D Main SW
Clock
Combination SW
∗The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.
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