change time TOYOTA AVENSIS 2003 Service Repair Manual

L1L2
D02612
L2
L1
D01201
L2
L1
D01202
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
01±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
NOTICE:
Do the torque checking with the lower limit value of the torque toleranc\
e.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets: When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always\
use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:(1) In case of tightening by extending the entire lengthof the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that\
vaporized fuel fills those places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,and do not spray much water so as to prevent slipping.
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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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B58265
Up
Down
1 2 3
4
5 6
B58557
Up
Down
12
3
4 5 6
70±8
±
WINDSHIELD/WINDOWGLASS/MIRROR POWER WINDOW CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
3. INSPECT FRONT DOOR WINDOW REGULATOR SUB±ASSY LH
(a) Inspect operation of the power window regulator.
(1) Apply battery voltage to the connector terminals.
(2) Check that the regulator smoothly operates.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
2Regulator moves upward
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
1Regulator moves
downward
(b) Inspect operation of the PTC inside the power window regulator motor.
NOTICE:
The work must be performed with the power window regu-
lator and door glass installed in the vehicle. (1) Set an electrical tester DC 400 A probe to the wireharness of terminal 4 or 6.
NOTICE:
Match the arrow mark of the probe with the current direc-
tion. (2) Fully close the door glass by operating the powerwindow switch and keep the door glass there for
approximately 60 seconds.
(3) Try to operate the power window past the fully
closed position using the power window switch and
measure the time until the electrical current
changes into 1 A from 16 to 34 A (Inspection of cur-
rent shut±off).
Standard: Less than 1 second
(4) Check that the door glass goes down when the
power window regulator switch is pushed DOWN.
If the result is not as specified, replace the regulator sub±assy.
4. INSPECT FRONT DOOR WINDOW REGULATOR SUB±ASSY RH
(a) Inspect operation of the power window regulator.
(1) Apply battery voltage to the connector terminals.
(2) Check that the regulator smoothly operates.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
2Regulator moves upward
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
1Regulator moves
downward
(b) Inspect operation of the PTC inside the power window regulator motor.
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B58266
12 3
4 56
Up
Down
±
WINDSHIELD/WINDOWGLASS/MIRROR POWER WINDOW CONTROL SYSTEM
70±9
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:
The work must be performed with the power window regu-
lator and door glass installed in the vehicle.
(1) Set an electrical tester DC 400 A probe to the wireharness of terminal 4 or 6.
NOTICE:
Match the arrow mark of the probe with the current direc-
tion. (2) Fully close the door glass by operating the powerwindow switch and keep the door glass there for
approximately 60 seconds.
(3) Try to operate the power window past the fully
closed position using the power window switch and
measure the time until the electrical current
changes into 1 A from 16 to 34 A (Inspection of cur-
rent shut±off).
Standard: Less than 1 second
(4) Check that the door glass goes down when the power window regulator switch is pushed DOWN.
If the result is not as specified, replace the regulator sub±assy.
5. INSPECT REAR DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) Inspect operation of the power window regulator motor. (1) Apply battery voltage to the connector terminals.
(2) Check that the regulator smoothly operates.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
2Regulator moves upward
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
1Regulator moves
downward
(b) Inspect operation of the PTC inside the power window regulator motor.
NOTICE:
The work must be performed with the power window regu-
lator and door glass installed in the vehicle.
(1) Set an electrical tester DC 400 A probe to the wireharness of terminal 4 or 6.
NOTICE:
Match the arrow mark of the probe with the current direc-
tion.
(2) Fully close the door glass by operating the powerwindow switch and keep the door glass there for
approximately 60 seconds.
(3) Try to operate the power window past the fully closed position using the power window switch and
measure the time until the electrical current
changes into 1 A from 16 to 34 A (Inspection of cur-
rent shut±off).
Standard: Less than 1 second
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B58558
UpDown
12 3
4 56
B690245
2 1
3 5
3
2
1
70±10
±
WINDSHIELD/WINDOWGLASS/MIRROR POWER WINDOW CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(4) Check that the door glass goes down when the power window regulator switch is pushed DOWN.
If the result is not as specified, replace the regulator sub±assy.
6. INSPECT REAR DOOR WINDOW REGULATOR SUB±ASSY RH
(a) Inspect operation of the power window regulator. (1) Apply battery voltage to the connector terminals.
(2) Check that the regulator smoothly operates.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
2Regulator moves upward
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
1Regulator moves
downward
(b) Inspect operation of the PTC inside the power window regulator motor.
NOTICE:
The work must be performed with the power window regu-
lator and door glass installed in the vehicle. (1) Set a electrical tester DC 400 A probe to the wireharness of terminal 4 or 6.
NOTICE:
Match the arrow mark of the probe with the current direc-
tion. (2) Fully close the door glass by operating the powerwindow switch and keep the door glass there for
approximately 60 seconds.
(3) Try to operate the power window past the fully
closed position using the power window switch and
measure the time until the electrical current
changes into 1 A from 16 to 34 A (Inspection of cur-
rent shut±off).
Standard: Less than 1 second
(4) Check that the door glass goes down when the power window regulator switch is pushed DOWN.
If the result is not as specified, replace the regulator sub±assy.
7. INSPECT IG1 RELAY
(a) Check resistance of the relay. Standard:
Tester ConnectionSpecified Condition
10 k or higher
3 ± 5Below 1 
(When battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay.
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760WE±01
B67742
B67741
Front SideRear Side
1.3 (0.051)
mm (in.)
A
A
A ± A
4.8 (0.189)
1.5 (0.059) A ± A A
A
4.6 (1.811)
76±26
±
EXTERIOR/INTERIOR TRIM ROOF DRIP SIDE FINISH MOULDING CENTER LH
AVENSIS REPAIR MANUAL (RM1018E)
ROOF DRIP SIDE FINISH MOULDING CENTER LH
REPLACEMENT
HINT:
Use the same procedures on the RH side as on the LH side. 1. REMOVE ROOF DRIP SIDE FINISH MOULDINGCENTER LH
(a) Put the protective tape around the circumference of the moulding.
(b) Using a remover for the roof moulding, release the disen-
gage the clips both in the front and rear ends of the mould-
ing, and then remove the moulding.
NOTICE:

Do not remove the clips.

If that the clips are damaged or removed accidentally,
exchange them for supplied ones.
2. INSTALL ROOF DRIP SIDE FINISH MOULDING CENTER LH
NOTICE:
Only when exchanging the clips.
(a) Remove the tape that remains on the mounting surface
of the body, and then clean the surface with white gaso-
line.
(b) Using a heat light, heat up the clip installation surfaces of the body and moulding.
Heating temperature:
Body40 ± 60 C (104 ± 140 F)
Moulding20 ± 30C (68 ± 86 F)
NOTICE:
Do not heat the moulding and body excessively.
(c) Set the supplied clips in the positions as shown in the il-
lustration and press±fit them by hand to install them.
NOTICE:
Install the moulding when 30 minutes or more have passed
after press±fitting the clips.
HINT:

Initial hardening time: 30 minutes

Perfect hardening time: 24 hours
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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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