center TOYOTA AVENSIS 2003 Service Repair Manual

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.
http://vnx.su

010B5±11
D25082
Rubber Attachment
D27697
: SUPPORT POSITION, PAN
TOGRAPH JACK POSITION
: CENTER OF VEHICLE GRAVITY
(unload condition)
: JACK POSITION
±
INTRODUCTION REPAIR INSTRUCTION
01±19
AVENSIS REPAIR MANUAL (RM1018E)
VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP
(a) As a rule, the vehicle must be unloaded when jacking up. Never jack up o\
r lift up the vehicle loaded
with things of heavy weight.
(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling,\
or hold the jacking support
location using the mission jack.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the instruction manual for a safety operation.
(b) Do not damage tires or wheels with a free wheel beam.
(c) Using a wheel stopper, fix the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in the flat place using a wheel stopper at all times.
(b) Use a safety stand with a rubber attachment, as shownin the illustration.
(c) Support the specified location with a jack and safety stand accurately.
(d) When jacking up the front wheels, release the parking
brake and place wheel stoppers only behind the rear
wheels. When jacking up the rear wheels, place wheel
stoppers only in front of the front wheels.
(e) Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with a safety stand.
(f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels that contact ground.
(g) When jacking down the vehicle with its front wheels jacked up, release t\
he parking brake and place wheel stoppers only in front of the rear wheels. When jacking down the v\
ehicle with its rear wheels
jacked up, place wheel stoppers only behind the front wheels.
http://vnx.su

D30400
Swing Arm Type Lift
Plate Type LiftCenter of Lift
: CENTER OF VEHICLE
GRAVITY (unloaded condition) Rubber Attachment
AttachmentBAL
Attachment Dimensions
85 mm (3.35 in.)
200 mm (7.87 in.)
100 mm (3.94 in.) 70 mm
(2.76 in.)
C
01±20
±
INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
4. NOTICE FOR USING SWING ARM TYPE LIFT
(a) Follow the instruction manual of the lift for a safe operation.
(b) Use a cradle with a rubber attachment, as shown in the illustration.
(c) Set in the vehicle so as to make its center of gravity as close as possible\
to the center of the lift. (ºLº becomes short.)
(d) Place the vehicle horizontally by adjusting the height of the cradle, and match th\
e groove of the cradle and the safety stand support location accurately.
(e) Be sure to lock the swing arm during the operation.
(f) Lift the vehicle up until the tires float, and shake the vehicle to make\
sure that the vehicle is stable.
5. NOTICE FOR USING PLATE TYPE LIFT
(a) Follow the instruction manual of the lift for a safe operation.
(b) Use a plate lift attachment.
(c) Be sure to set the vehicle to the specified position.
Right and left set position
Place the vehicle over the center of the lift.
Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (\
A and C).

Align the attachment upper end (B) with the rocker flange front side n\
otch.
(d) Lift the vehicle up until the tires float a bit, and shake the vehicle t\
o make sure that the vehicle is stable.
http://vnx.su

010B9±11
±
INTRODUCTION TERMS
01±37
AVENSIS REPAIR MANUAL (RM1018E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CANController Area Network
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
http://vnx.su

01±40
±
INTRODUCTION TERMS
AVENSIS REPAIR MANUAL (RM1018E) Abbreviations Meaning
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn±board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
http://vnx.su

022KA±01
02±18
±
PREPARATION COOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
PREPARATION
SST
09023±12700Union Nut Wrench 17mmWATER PUMP ASSY(1CD±FTV)
09213±54015Crankshaft Pulley Holding ToolWATER PUMP ASSY(1CD±FTV)
(90105±08076)BoltWATER PUMP ASSY(1CD±FTV)
09249±63010Torque Wrench AdaptorWATER PUMP ASSY(1AZ±FE)
THERMOSTAT(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
THERMOSTAT(1AZ±FSE)
09330±00021Companion Flange Holding ToolWATER PUMP ASSY(1CD±FTV)
09950±50013Puller C SetWATER PUMP ASSY(1CD±FTV)
(09951±05010)Hanger 150WATER PUMP ASSY(1CD±FTV)
(09952±05010)Slide ArmWATER PUMP ASSY(1CD±FTV)
(09953±05020)Center Bolt 150WATER PUMP ASSY(1CD±FTV)
(09954±05021)Claw No.2WATER PUMP ASSY(1CD±FTV)
(09954±05031)Claw No.3WATER PUMP ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetWATER PUMP ASSY(1AZ±FE)
WATER PUMP ASSY(1AZ±FSE)
WATER PUMP ASSY(1CD±FTV)
http://vnx.su

02±30
±
PREPARATION DRIVE SHAFT / PROPELLER SHAFT
AVENSIS REPAIR MANUAL (RM1018E)
09610±20012Pitman Arm PullerREAR AXLE CARRIER SUB±ASSY
LH
09628±10011Ball Joint PullerREAR AXLE LH HUB BOLT
FRONT AXLE LH HUB BOLT
09628±62011Boll Joint PullerFRONT AXLE HUB SUB±ASSY LH
REAR AXLE CARRIER SUB±ASSY
LH
FRONT DRIVE SHAFT
09710±04081BaseFRONT DRIVE SHAFT
09718±00010Shoe Hold Down Spring DriverREAR AXLE CARRIER SUB±ASSY
LH
09726±40010Lower Control Shaft Bearing
ReplacerFRONT DRIVE SHAFT
09930±00010Drive Shaft Nut ChiselFRONT AXLE HUB SUB±ASSY LH
FRONT DRIVE SHAFT
09950±00020Bearing RemoverFRONT DRIVE SHAFT
09950±40011Puller B SetFRONT AXLE HUB SUB±ASSY LH
(09951±04020)Hanger 200FRONT AXLE HUB SUB±ASSY LH
(09952±04010)Slide ArmFRONT AXLE HUB SUB±ASSY LH
(09953±04030)Center Bolt 200FRONT AXLE HUB SUB±ASSY LH
(09954±04010)Arm 25FRONT AXLE HUB SUB±ASSY LH
http://vnx.su

02±12
±
PREPARATION ENGINE MECHANICAL
AVENSIS REPAIR MANUAL (RM1018E)
09950±50013Puller C SetCHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09951±05010)Hanger 150CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09952±05010)Slide ArmCHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09953±05010)Center Bolt 100CRANKSHAFT SEAL(1CD±FTV)
http://vnx.su

±
PREPARATION ENGINE MECHANICAL
02±13
AVENSIS REPAIR MANUAL (RM1018E)
(09953±05020)Center Bolt 150CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
(09954±05021)Claw No.2CHAIN SUB±ASSY(1AZ±FE)
CYLINDER HEAD GASKET(1AZ±FE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FE)
CHAIN SUB±ASSY(1AZ±FSE)
CYLINDER HEAD
GASKET(1AZ±FSE)
TIMING GEAR CASE OR TIMING
CHAIN CASE OIL SEAL(1AZ±FSE)
CRANKSHAFT SEAL(1CD±FTV)
(09954±05031)Claw No.3TIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
09950±70010Handle SetENGINE REAR OIL SEAL(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FSE)
ENGINE REAR OIL SEAL(1CD±FTV)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
(09951±07100)Handle 100ENGINE REAR OIL SEAL(1AZ±FE)
ENGINE REAR OIL SEAL(1AZ±FSE)
ENGINE REAR OIL SEAL(1CD±FTV)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
09960±10010Variable Pin Wrench SetTIMING BELT(1CD±FTV)
CAMSHAFT(1CD±FTV)
CYLINDER HEAD
GASKET(1CD±FTV)
CRANKSHAFT SEAL(1CD±FTV)
PARTIAL ENGINE ASSY(1CD±FTV)
PARTIAL ENGINE
ASSY(1ZZ±FE/3ZZ±FE)
CHAIN
SUB±ASSY(1ZZ±FE/3ZZ±FE)
CYLINDER HEAD
GASKET(1ZZ±FE/3ZZ±FE)
TIMING CHAIN OR BELT COVER OIL
SEAL(1ZZ±FE/3ZZ±FE)
ENGINE REAR OIL
SEAL(1ZZ±FE/3ZZ±FE)
http://vnx.su

±
PREPARATION FUEL
02±5
AVENSIS REPAIR MANUAL (RM1018E)
09808±14010Fuel Sender Gauge Tool AssyFUEL TANK ASSY(DIESEL)
FUEL PUMP ASSY(GASOLINE)
FUEL TANK ASSY(GASOLINE)
09842±30080Wire ºHº EFI InspectionFUEL SYSTEM(1AZ±FE)
FUEL SYSTEM(1ZZ±FE/3ZZ±FE)
09950±50013Puller C SetINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09951±05010)Hanger 150INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09952±05010)Slide ArmINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09953±05020)Center Bolt 150INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09954±05021)Claw No.2INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09954±05031)Claw No.3INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09960±10010Variable Pin Wrench SetINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09962±01000)Variable Pin Wrench Arm AssyINJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
(09963±01000)Pin 10INJECTION OR SUPPLY PUMP
ASSY(1CD±FTV)
09992±00242Turbocharger Pressure GaugeINJECTOR ASSY(1CD±FTV)
Recomended Tools
09042±00020Torx Socket T40FUEL INJECTOR ASSY(1AZ±FSE)
http://vnx.su