2002 TOYOTA AVENSIS check oil

670SL±01
BE4029
Tester Probe
Tin FoilHeat Wire
E32576
BE0150
Repair Point
Masking TapeBroken
Wire
BE0151
Repair PointFine Tip Brush
Glass
± AUDIO & VISUAL SYSTEMWINDOW GLASS (ANTENNA WIRE)
67±33
AVENSIS REPAIR MANUAL (RM1018E)
WINDOW GLASS (ANTENNA WIRE)
REPAIR
1. INSPECT WINDOW GLASS (ANTENNA WIRE)
NOTICE:
When cleaning the glass, wipe it in the direction of the wire
with a soft and dry cloth. Take care not to damage the wire.
Do not use detergents or glass cleaners with abrasive in-
gredients. When measuring voltage, wind a piece of tin foil
around the tip of the tester probe and press the foil against
the wire with your finger, as shown in the illustration.
(a) Check the continuity, at the center of each antenna wire,
as shown in the illustration.
2. REPAIR WINDOW GLASS (ANTENNA WIRE)
(a) Clean the broken wire tips with a grease, wax and silicone
remover.
(b) Place the masking tape along both sides of the wire to be
repaired.
(c) Thoroughly mix the repair agent (Dupont paste No.4817).
(d) Using a fine tip brush, apply a small amount of the mixture
to the wire.
(e) After a few minutes, remove the masking tape.
(f) Do not repair the defogger wire for at least 24 hours after-
wards.

3201B±12
32±2
±
BRAKE BRAKE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the probability of the
problems in descending order. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
3. Fluid leaks in brake system
4. Air in brake system
5. Piston seals (Worn or damaged)
6. Brake master cylinder (faulty)
7. Brake booster push rod (Out of adjustment) ±
32±4
32±41
32±47
32±13
32±13
Brake drag
1. Brake pedal free play (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Disk brake pad (Cracked or distorted)
5. Piston (Stuck or Frozen)
6. Brake booster push rod (Out adjustment)
7. Vacuum leaks in brake booster system
8. Brake master cylinder (Faulty)32±6
33±2
33±2
32±41
32±47
32±41
32±47
32±13
32±17
32±21
32±13
Brake pull
1. Piston (Stuck or Frozen)
2. Pad or lining (Oily)
3. Disc (Scored)
4. Pad (Cracked or distorted) 32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
Hard pedal but brake inefficient
1. Fluid leaks in brake system
2. Air in brake system
3. Pad (Worn)
4. Pad (Cracked or distorted)
5. Pad (Oily)
6. Pad (Glazed)
7. Disc (Scored)
8. Booster push rod (Out of adjustment)
9. Vacuum leaks for booster system ±
32±4
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±13
32±17
32±21

F45419
Cylinder Slide Pin
Lithium soap base glycol grease
F45421
Union Bolt
±
BRAKE FRONT BRAKE
32±45
AVENSIS REPAIR MANUAL (RM1018E)
24. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Apply lithium soap base glycol grease to the a new front
disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the bot- tom side of the front disc brake cylinder slide pin (No.2).
(c) Apply lithium soap base glycol grease to the sliding part
and the sealing surface of the 2 cylinder slide pins.
(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH.
25. INSTALL FRONT DISC BRAKE PAD KIT
(a) Install the 2 front disc brake pad support plates (No.1) and 2 front disc bra\
ke pad support plates (No.2) to the front disc brake cylinder mounting LH.
(b) Install the disc brake pad kit front to the front disc brake cylinder mo\
unting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads an\
d the disc.
26. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder assy LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the disc
brake cylinder assy LH.
27.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
28.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
29.BLEED BRAKE LINE (See page 32±4)
30.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
31. CHECK BRAKE FLUID LEAKAGE
32. INSTALL FRONT WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

32092±05
G24249
Oil Hose
Vacuum HoseO±Ring
Vacuum Pump Assy
Vacuum Hose
Check Valve Sub±assy
Vacuum Pump Union Gasket
Straight Pin
Vacuum Pump End Cover Snap Ring
CouplingVaccup Pump Housing
Vacuum pump Blade A
Straight Pin
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part

O±Ring



Gasket

Gasket


O±Ring

Union bolt
7.8 (80, 69 in.
lbf)
7.8 (80, 69 in.
lbf)
7.8 (80, 69 in.
lbf)
14 (140, 10)
21 (214, 15)
21 (214, 15)
Air Cleaner Cap Sub±assy
74 (750, 54)
Connector
Vacuum pump Rotor
32±34
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

320W2±01
G24251
Vacuum Hose
Oil Hose
F45364
F08966
F08967
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±35
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
1. REMOVE AIR CLEANER CAP SUB±ASSY
2. REMOVE VACUUM PUMP ASSY
(a) Disconnect the 2 vacuum hoses and oil hose from the
vacuum pump assy.
(b) Remove the 2 bolts and vacuum pump assy.
(c) Remove the 2 O±rings from the vacuum pump assy.
3. INSPECT VACUUM PUMP ASSY
(a) Turn the coupling counterclockwise direction by hand
when seeing from the coupling direction and check for
any abnormality such as dragging or torque fluctuation.
NOTICE:
Pay coupling attention, because the engine oil remained in
the pump escapes while coupling is turning.
4. REMOVE VACUUM PUMP UNION
(a) Using soft jaws on a vise, hold the vacuum pump assy in
a vise.
NOTICE:
Do not tighten the vise excessively and perform the work
while holding the vacuum pump assy by hand.
(b) Remove the union bolt, vacuum pump union and 2 gas-
kets.
5. REMOVE CHECK VALVE SUB±ASSY
(a) Remove the check valve sub±assy and gasket.

F05383
Air
Hose Side Vacuum Pump Side
Air
F08981
F08982
New O±Ring
F08970
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±37
AVENSIS REPAIR MANUAL (RM1018E)
10. INSPECT CHECK VALVE SUB±ASSY
(a) Check that air flows from the hose side to the pump side.
(b) Check that air does not flow from the pump side to the
hose side.
NOTICE:
Block off the 4 holes on the side surface of the check valve
when checking.
If necessary, replace the check valve.
11. INSTALL VACUUM PUMP COUPLING
(a) Place the vacuum pump coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
12. INSTALL VACUUM PUMP ROTOR SUB±ASSY
(a) Coat the rotor with engine oil, and install it to the rotor shaft.
13. INSTALL VACUUM PUMP BLADE A
(a) Apply the engine oil to the rotor, and install the rotor in the
housing.
(b) Apply the engine oil to the 5 new blades.
(c) Install the 5 blades with the round end facing outward.
NOTICE:
Install so that the blade attaches on the housing.
(d) Coat 2 new O±rings with engine oil, and install them on
the housing.
(e) Using soft jaws on the vise, place the vacuum pump on
the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(f) Place the end cover, and temporarily install the 3 bolts.
(g) Using a pin punch and hammer, drive in the 2 straight
pins.
NOTICE:
Install so that the blade and end cover of the eccentric ring
does not interfere with each other.

G24250
Vacuum HoseNew O±Ring
Oil Hose
F45366
Vacuum Gauge
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±39
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL VACUUM PUMP ASSY
(a) Coat 2 new O±rings with engine oil, and install them to the
vacuum pump assy.
(b) Install the vacuum pump assy aligning the coupling with
the slit of the camshaft.
(c) Install the 2 bolts.
Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(d) Connect 2 vacuum hoses and oil hose.
18. INSPECT CHECK VACUUM PUMP OPERATION
(a) Slide the clip, then disconnect the vacuum hose from vac-
uum pump assy.
(b) Connect the hose of the vacuum gauge to the vacuum
pump assy.
(c) Block off another hose of the vacuum gauge with the hose
clamp No.2.
(d) Start the engine and warm it up for more than 2 minutes.
(e) With the engine idle, check the negative pressure of the
vacuum pump assy.
Standard: More than 650 mmHg (86.7 kPa).
(f) Remove the vacuum gauge from the vacuum pump assy.
(g) Connect the vacuum hose with the clip to the vacuum
pump assy.
19. INSTALL AIR CLEANER CAP SUB±ASSY

4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26