sst TOYOTA AVENSIS 2003 Service Repair Manual

010B2±13
N17080
Filler Cap
Float
Reservoir Tank
Grommet
Clip
Slotted Spring Pin
: Specified torque

Non±reusable part Cylinder
Piston
Push Rod
Washer
Snap Ring
Boot


Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
±
INTRODUCTION HOW TO USE THIS MANUAL
01±1
AVENSIS REPAIR MANUAL (RM1018E)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is made in accordance with SAE J2008.
(b) Generally, repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking \
and Adjusting
3. Final Inspection
(c) This manual explains the 1st process of ºDiagnosisº (found in the ºDiagnosticsº section), the 2nd
pro-
cess of ºRemoving and Installing, Replacing, Disassembling, Installing and Ch\
ecking, and Adjustingº,
but the 3rd process of ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a refe\
rence to help you find the item to be repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM\
) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are requir\
ed and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) Component drawing is placed under the title where necessary.
(b) Non±reusable parts, grease application area, precoated parts and tigh\
tening torque are specified in the component drawings.
Example:
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010LF±01






D25016
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INTRODUCTION REPAIR INSTRUCTION
01±5
AVENSIS REPAIR MANUAL (RM1018E)
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
1Looks
Always wear a clean uniform.

Hat and safety shoes must be worn.
2Vehicle protection
Set 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 gauge
Before 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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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 N
mkgf
cmft
lbf
TTorque N
mkgf
cmft
lbf
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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D25096
Example:CORRECTWRONG
Z13950
Example:
D27522
Example: CORRECT WRONG
±
INTRODUCTIONREPAIR INSTRUCTION
01±11
AVENSIS REPAIR MANUAL (RM1018E)
(6)When disposing the vehicle or the horn button assembly alone, the airbag\
should be inflated us-
ing an SST before disposal (See page 60±19).
Perform the operation in a safe place away from electrical noise.
(d)INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (1)Always place a removed or new instrument panel passenger airbag assembly\
with the airbaginflation direction facing upward. Placing the airbag assembly with the airbag inflation direction
facing downward could cause a serious accident if the airbag deploys.
(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 instrument panel passenger airbag assembly\
and the airbag door should not be cleaned with detergents of any kind.
(4)Store the airbag 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\
) installed on the as- sembly before starting work.
(6)When disposing of a vehicle or the airbag assembly unit, the airbag should be deployed using\
SST before disposal (See page 60±30).
Activate in a safe place away from electrical noise.
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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 93
C (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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D30399
Example:CORRECT WRONG
D30398
Example:
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INTRODUCTIONREPAIR INSTRUCTION
01±13
AVENSIS REPAIR MANUAL (RM1018E)
(f)INSTRUMENT PANEL LOWER AIRBAG ASSEMBLY
(1)Always store a removed or new instrument panel lower airbag assembly with the \
airbag inflatingdirection facing 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 instrument panel lower airbag assembly and\
the airbag door should not be cleaned with detergents of any kind.
(4)Store the instrument panel lower airbag assembly where the ambient temperature remains be- low 93
C (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
instrument panel lower airbag assembly before starting work.
(6)When disposing of a vehicle or the instrument panel lower airbag assembly alone, the airbag should be inflated using an SST before disposal (See page 60±55).
Perform the operation in a safe place away from electrical noise.
(g) CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keepit in a safe place.
NOTICE:
Protection bag is not re±useable.
CAUTION:
Never disassemble the curtain shield airbag assembly. (2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, whichis very dangerous).
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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 93
C (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 80
C (176
F)
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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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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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
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022L4±02
02±36
±
PREPARATION AUTOMATIC TRANSMISSION / TRANS
AVENSIS REPAIR MANUAL (RM1018E)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetTRANSMISSION CONTROL CABLE
ASSY
(07117±58060)Refrigerant Drain Service ValveTRANSMISSION CONTROL CABLE
ASSY
(07117±58070)T±JointTRANSMISSION CONTROL CABLE
ASSY
(07117±58080)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±58090)Quick Disconnect AdapterTRANSMISSION CONTROL CABLE
ASSY
(07117±78050)Refrigerant Charging GaugeTRANSMISSION CONTROL CABLE
ASSY
(07117±88060)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88070)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
(07117±88080)Refrigerant Charging HoseTRANSMISSION CONTROL CABLE
ASSY
09023±12700Union Nut Wrench 17mmAUTOMATIC TRANSAXLE
ASSY(U241E)
AUTOMATIC TRANSAXLE
ASSY(U341E)
09308±00010Oil Seal PullerFRONT DIFFERENTIAL OIL
SEAL(U241E)
FRONT DIFFERENTIAL OIL
SEAL(U341E)
09316±60011Transmission & Transfer Bearing
ReplacerFRONT DIFFERENTIAL OIL
SEAL(U241E)
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