2002 TOYOTA AVENSIS Repair Manual

D26819
EXCEPT 1CD±FTV Engine Type:
1CD±FTV Engine Type:
Release Hub Grease
±
CLUTCH CLUTCH UNIT (MTM)
42±29
AVENSIS REPAIR MANUAL (RM1018E)
16. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle assy.
Torque:
1ZZ±FE/3ZZ±FE/1CD±FTV Engine Type: 37 N
m (375 kgf
cm, 27 ft
lbf)
1AZ±FSE/1AZ±FE Engine Type: 47 N
m (480 kgf
cm, 35 ft
lbf)
17. INSTALL RELEASE BEARING HUB CLIP
18. INSTALL CLUTCH RELEASE FORK SUB±ASSY
(a) Apply the release hub grease to the release fork and re-lease bearing assy contact, release fork and push rod
contact, and release fork pivot points.
Sealant:
Part No. 08887±01806, RELEASE HUB GREASE or
equivalent
(b) Install the release fork to the release bearing assy.
19. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Apply the clutch spline grease to the input shaft spline. Sealant:
Part No. 08887±01706, CLUTCH SPLINE GREASE or equivalent
(b) Install the bearing to the release fork, and then install them to the tr\
ansaxle assy.
NOTICE:
After the installation, move the folk forward and backward to check that\
the release bearing slides
smoothly.
20. INSTALL CLUTCH RELEASE FORK BOOT
21. INSTALL MANUAL TRANSAXLE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 41±15)
(b)1AZ±FE, 1AZ±FSE Engine (See page 41±24)
(c)1CD±FTV Engine (See page 41±33)

69067±02
B67410
± COMMUNICATION SYSTEMHIGH PITCHED HORN ASSY
69±5
AVENSIS REPAIR MANUAL (RM1018E)
HIGH PITCHED HORN ASSY
REPLACEMENT
1. REMOVE HIGH PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL HIGH PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator support
upper, and then install the horn with the bolt.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the connector.

69064±02
B67409
Low Pitched HornHORN Relay
High Pitched Horn
Engine Room R/B No. 2Engine Room R/B

HORN Fuse
± COMMUNICATION SYSTEMHORN SYSTEM
69±1
AVENSIS REPAIR MANUAL (RM1018E)
HORN SYSTEM
LOCATION

69065±02
69±2
±
COMMUNICATION SYSTEM HORN SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee Page
Horn does not sound
1. Horn button switch
2. High pitched horn
3. Low pitched horn
4. HORN fuse
5. HORN relay
6. Wire harness±
69±3
69±3
69±3 ±

69066±02
B67416
B67417
B68374
21
5
3
± COMMUNICATION SYSTEMHORN SYSTEM
69±3
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT LOW PITCHED HORN ASSY
(a) Check operation of the horn.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+) Terminal 1
Battery positive (±) Horn bodyHorn sounds
If the result is not as specified, replace the horn assy.
2. INSPECT HIGH PITCHED HORN ASSY
(a) Check operation of the horn.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+) Terminal 1
Battery positive (±) Horn bodyHorn sounds
If the result is not as specified, replace the horn assy.
3. INSPECT HORN RELAY ASSY
(a) Remove the HORN relay from the engine room R/B No.
2.
(b) Check the horn relay resistance.
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 assy.

69068±02
B67411
69±4
± COMMUNICATION SYSTEMLOW PITCHED HORN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
LOW PITCHED HORN ASSY
REPLACEMENT
1. REMOVE LOW PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL LOW PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator support
upper, and then install the horn with the bolt.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(b) Connect the connector.

1600R±13
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
16±17
AVENSIS REPAIR MANUAL (RM1018E)
COOLING FAN SYSTEM (1AZ±FE)
ON±VEHICLE INSPECTION
HINT:
It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 77
C (171
F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor, and check for disconnection of
connectors or wire break between the cooling fan relay and engine coolant temperature sensor.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the
cooling fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 95.5
C (204
F))
(a) Start the engine, and raise coolant temperature to above 95.5
C (204
F).
HINT:
Coolant temperature is the detected value by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
3. INSPECT COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.
4. INSPECT COOLING FAN No.2 (With Air Conditioner)
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the cooling fan connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
5.2 to 8.2 A at 20
C (68
F) (M/T)
8.3 to 11.3 A at 20
C (68
F) (A/T)
(d) Reconnect the cooling fan connector.

160N3±01
E34090
A30519
E34090
16±18
± COOLINGCOOLING FAN SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT COOLING FAN RELAY
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
2. INSPECT COOLING FAN RELAY NO.2
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2
3 ± 4Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)
3. INSPECT COOLING FAN RELAY NO.3
(a) Continuity inspection.
(1) Using an ohmmeter, check for continuity between
each terminal.
Specified condition:
Terminal No.Specified condition
1 ± 2Continuity
No continuity
3 ± 5Continuity
(Apply battery voltage terminals 1 and 2)