open hood TOYOTA AVENSIS 2003 Service Repair Manual

410DT±01
D30082
13 (133, 10)Hood Sub±assy
Engine Cover Sub±assy No.1
Air Cleaner Assy
BatteryBattery Tray
Clip
Clip
Clip
Starter Assy
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
12 (120, 9)
Manual Transaxle Assy
46 (469, 34)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.

lbf)
Engine Room Cover Side
Radiator Support Opening Cover
44 (449, 32)
44 (449, 32)
Clutch Release Cylinder Assy
Starter
Connector
37 (380, 27)
13 (130, 9)
46 (469, 34)
8.4 (85, 74 in.
lbf)
46 (469, 34)
Transmission Control Cable Assy
Battery Clamp Sub±assy
5.0 (51, 44 in.
lbf)
9.0 (92, 80 in.
lbf)
Back±up Lamp Switch Connector
5.0 (51, 44 in.
lbf)
Clip
26 (260, 19)
40 (410, 30)
64 (653, 47)
52 (530, 38)
13 (131, 9)
41±22
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
COMPONENTS
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410DU±01
D30480
D30081
41±24
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUB±ASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19.REMOVE STARTER ASSY (See page 19±12) 20. SEPARATE WIRE HARNESS
(a) Remove the 3 bolts, and separate the 3 wire harnesses.
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D30080
41±30
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZ±FE/1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
55. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts. Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
59. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
60. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUB±ASSY Torque: 13 N
m (132 kgf
cm, 10 ft
lbf)
64.INSPECT HOOD SUB±ASSY (See page 75±2)
65.ADJUST HOOD SUB±ASSY (See page 75±2)
66.ADD TRANSAXLE OIL (See page 41±5)
67.INSPECT TRANSAXLE OIL (See page 41±2)
68. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
69.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
70.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page)See page 50±9)
71.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
72.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76.BLEED POWER STEERING FLUID (See page 51±4)
77.CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 51±4)
78.INSPECT FLUID LEAK (See page 51±4)
79.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
82. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
83.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)
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410DV±01
D30475
13 (133, 10)Hood Sub±assy
Radiator Reserve Tank Assy
Engine Cover No.1
5.0 (51, 44 in.
lbf)
7.0 (71, 62 in.
lbf)
Air Cleaner Assy
Battery Clamp
Sub±assy
3.5 (36, 31 in.
lbf)
Battery
Battery Tray
Clip
Clip
Clip
Floor Shift Transmission
Control Cable Assy
Starter Assy
Starter Connector
Ground Cable
64 (653, 47)
80 (816, 59)
52 (530, 38)
18 (184, 13)
Manual Transmission
Case Protector
64 (653, 47)
40 (408, 30)
20 (200, 14)
8.0 (82, 71 in.
lbf)
40 (408, 30)
64 (653, 47)

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
12 (120, 9)
5.0 (51, 44 in.

lbf)
64 (653, 47)
Manual Transaxle Assy
13 (133, 10)
37 (380, 27)
46 (469, 34)
13 (130, 9)
Transverse Engine
Engine Mounting Insulator
9.0 (92, 80 in.
lbf)
8.0 (82, 71 in.
lbf)
6.0 (61, 53 in.
lbf)
52 (530, 38)
25 (255, 18)
Air Tube No.1
25 (255, 18)
Engine Room Cover Side
Radiator Support
Opening Cover
Clip
13 (131, 9)
12 (120, 9)
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±31
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1CD±FTV)
COMPONENTS
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410DY±01
D26902
D26903
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±33
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER RH
8. REMOVE ENGINE UNDER COVER LH
9. DRAIN TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18.REMOVE AIR TUBE NO.1 (See page 14±286)
19. SEPARATE RADIATOR RESERVE TANK ASSY
(a) Remove the 2 bolts, separate the radiator reserve tankassy.
20. REMOVE STARTER ASSY
(a) Remove the nut, disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.
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410DS±01
D30478
Battery Clamp Sub±assyBattery Tray
Charcoal Canister Assy
Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2 Starter Assy Back±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
Clip
Clip
37 (380, 27)
Starter Connector
Transverse Engine
Engine Mounting Insulator
52 (530, 38)
52 (530, 38)
Ground Cable


Gasket
7.0 (71, 62 in.
lbf)
Filler Plug
37 (380, 27)
23 (230, 17)
47 (479, 35)
N´m (kgf´cm, ft´lbf) : Specified torque
19 (195, 14)
13 (130, 9)
64 (653, 47)
64 (653, 47)
5.0 (51, 44 in.
lbf)

Non±reusable part
5.0 (51, 44 in.
lbf)
14 (141, 10)
13 (133, 10)
13 (131, 9)
5.0 (51, 44 in.
lbf)
26 (260, 19)
25 (255, 18)
80 (816, 59)
26 (260, 19)
23 (230, 17)
Engine Room Cover Side
Radiator Support Opening Cover
40 (410, 30)
39 (400, 29)
Manual Transaxle Assy
64 (653, 47)
Battery
Clutch Release Cylinder Assy
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS
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± 50 g (± 1.76 oz.)
I37057
0.1 (1.0)0.4 (4.0)
0.3 (3.0)
0.2 (2.0) MPa (kgf/cm
2)
Pressure on low pressure side
Outside temperature
0
C ( F)
15 (59) 20 (68)
30 (86)
25 (77) 35 (95)
0 g (0 oz.)
(Standard)
+ 50 g (+ 1.76 oz.)
±
HEATER & AIR CONDITIONER REFRIGERANT
55±31
AVENSIS REPAIR MANUAL (RM1018E)
3. w/ Hot gas heater:
INSPECT REFRIGERANT VOLUME
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the the manifold gauge pres-
sure when these conditions are established.
Test conditions:

Engine is at idle.

Blower speed control switch is at ºHIº.

Temperature control dial is at ºMAX. COOLº.

Engine has been warmed up.

All doors are fully open.

Hood is fully open.

Air inlet mode selector damper is at RECIRE.

Air outlet damper is at FACE.

Outside temperature is 15 ± 35
C (59± 95

F).
(b) Check refrigerant volume according to the graph below.
RangeAmount of refrigerantCorrective actions
Except range belowInsufficient or excessive
Supply refrigerant until low
pressure become within the standard
50 g
(
1.76 oz.), or remove
refrigerant and then sup- ply proper amount of re-
frigerant
Standard
50 g
(
1.76 oz.)Proper±
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I35337
I35336
I35339
I35340
55±94
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
sub±assy from the w/ receiver condenser assy.
(b) Remove 2 O±rings from the discharge tube sub±assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
6. REMOVE LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube sub±assy B from w/ receiver condenser assy.
(b) Remove the O±ring from the liquid tube sub±assy B.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
7. REMOVE HOOD LOCK ASSY
(a) Remove the 3 bolts and the hood lock assy.
8.REMOVE HIGH PITCHED HORN ASSY (See page 69±5)
9.REMOVE LOW PITCHED HORN ASSY (See page 69±4) 10. REMOVE HOOD LOCK SUPPORT BRACE
(a) Remove the 5 bolts and the hood lock support brace.
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I35337
I35336
I35339
I35340
55±94
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
sub±assy from the w/ receiver condenser assy.
(b) Remove 2 O±rings from the discharge tube sub±assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
6. REMOVE LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube sub±assy B from w/ receiver condenser assy.
(b) Remove the O±ring from the liquid tube sub±assy B.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
7. REMOVE HOOD LOCK ASSY
(a) Remove the 3 bolts and the hood lock assy.
8.REMOVE HIGH PITCHED HORN ASSY (See page 69±5)
9.REMOVE LOW PITCHED HORN ASSY (See page 69±4) 10. REMOVE HOOD LOCK SUPPORT BRACE
(a) Remove the 5 bolts and the hood lock support brace.
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730G8±01
±
THEFT DETERRENT & DOOR LOCK THEFT DETERRENT SYSTEM
73±31
AVENSIS REPAIR MANUAL (RM1018E)
THEFT DETERRENT SYSTEM
ON±VEHICLE INSPECTION
1. OUTLINE OF THEFT DETERRENT SYSTEM
(a) When the theft deterrent system detects that the vehicle is being tampered with, the sy\
stem sets off
the alarm, causing the horns to sound and the lights to light up or blink in order to alert\
people around
the vehicle to the theft.
(b) The theft deterrent system has an active arming mode; a disarmed state, an \
arming preparation state,
an armed state and an alarm sounding state.
(1) Disarmed state:

The alarm function is not operating.

The theft deterrent system is not operating.
(2) Arming preparation state:

The time until the system goes into the armed state.

The theft deterrent system is not operating.
(3) Armed state:

The theft deterrent system is operating.
HINT:
If the vehicle remains in a condition that sets off the alarm (any door remains open, engine hood remains
open, ignition switch remains directly connected) after the alarm ends,\
the alarm will be set off repeatedly
a maximum of 10 times for every one of the above specified conditions. Alarm time: Approx. 27.5 sec. x 10
(4) Alarm sounding state:When the theft deterrent system detects that the vehicle is being tampered w\
ith while in the
armed state, the system causes the horns to sound and the lights to light up or blink in order t\
o
alert people around the vehicle to the theft.
Refer to table below for alarm method and time:
Hazard Warning LampBlinking (Cycle of flasher relay)
Alarm MethodRoom LampIlluminatingAlarm MethodVehicle HornSounding (Cycle of 0.4 sec.)
Self±power SirenSounding (Cycle of 0.4 sec.)
Alarm TimeApprox. 27.5 sec. (Maximum 10 times)
HINT:
If any of the doors are unlocked with no key in the ignition key cylinde\
r during the armed state, a forced door
lock signal will be output (See step 3).
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