2002 TOYOTA AVENSIS Repair Manual

L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
±
INTRODUCTION REPAIR 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
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
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.

D30401
Mark
01±10
±
INTRODUCTION REPAIR 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.

D25096
Example:CORRECTWRONG
Z13950
Example:
D27522
Example: CORRECT WRONG
±
INTRODUCTION REPAIR 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.

Z13951
Example:
D26612
Example:CORRECT WRONG
B01546
Example:
01±12
±
INTRODUCTION REPAIR 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.

D30399
Example:CORRECT WRONG
D30398
Example:
±
INTRODUCTION REPAIR 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).

D26602
Example:CORRECT WRONG
Clear Plastic Bag
D26603
Example:
01±14
±
INTRODUCTION REPAIR 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.

D26613
Example:
D25080
Negative (±)
Terminal
± INTRODUCTIONREPAIR INSTRUCTION
01±15
AVENSIS REPAIR MANUAL (RM1018E)
(8) Oil or water should not be put on the front seat outer belt and the front seat outer belt should be
cleaned with the appropriate detergents.
(i) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved in a collision where the SRS has deployed.
(2) The connectors to the airbag sensor assembly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted to the floor, it could cause an undesired ignition of the supple-
mental restraint system.
(3) Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº
position and the negative (±) terminal cable is disconnected from the battery, even if only loosen-
ing the set bolts of the airbag sensor assembly.
(j) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All connec-
tors in the system are a standard yellow color. If the SRS wire harness becomes disconnected
or the connector becomes broken due to an accident, etc., repair or replace it.
3. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (±) terminal cable beforehand in
order to prevent it from shorting and burning out.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF, and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal.
(3) When the battery terminal cable is removed, the
memories of the clock, radio, DTCs, etc. are erased.
So before removing it, check them and make a note
of their settings.
(4) When the battery negative (±) terminal cable is dis-
connected, memories of various systems are
erased. Therefore, refer to the PRE±CHECK for
each system to make sure whether or not the sys-
tem needs to be initialized after the battery negative

D01556
WRONG
D01563
01±16
± INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(±) terminal cable is disconnected. If necessary, be
sure to initialize the system.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless
absolutely necessary (If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity).
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission±re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation and without anything that could cause combustion
around you such as a welder, grinder, drill, electric motor or stove.
(2) Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel
will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operations.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray much water so as to prevent slipping.
(3) Never use any electric equipment like an electric motor or a working light, as they may create
sparks or a high temperature.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of shop rags containing fuel deposits separately.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal tip is mixed in the inlet pass, this may give a
bad effect to the engine and turbocharger.
(b) When removing and installing the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean waste cloth or gum tape.
(c) When installing the inlet system parts, check that there is
no mixing of a metal tip.