2003 TOYOTA AVENSIS transmission

D26894
Serrate Part
D30070
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±9
AVENSIS REPAIR MANUAL (RM1018E)
(d) Connect the end of the select cable to the shift lever assy
and install the clip.
NOTICE:

The serrate part of the select cable point should face
upward when the select cable point is connected.

The clip should be inserted to the direction as shown
in the illustration.
(e) Connect the end of the shift cable to the shift lever assy.
(f) Connect the control cable assy with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(g) Connect the 2 cable ends, install the 2 clips.
(h) Install the 2 clips to the control cable bracket.
6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Install the heat insulator No.1 with the 3 nuts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
7. INSTALL EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
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\b
D30389
AZ Series:1CD±FTV:
No.1 Engine Hanger
No.2 Engine Hanger
No.1 Engine Hanger
No.2 Engine Hanger
No.1 Engine
Hanger UPR
D29969
C94595
51±38
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
15.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
16. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Perform the same procedure on the other side.
17. REMOVE HOOD SUB±ASSY
18. REMOVE CYLINDER HEAD COVER SUB±ASSY 19. SUSPEND ENGINE ASSEMBLY
(a) Install the 2 or 3 engine hangers with the bolts in the cor-rect direction.
Parts No. :
AZ Series:1CD±FTV:
No.1 Engine Hanger12281±2801012281±27050
No.1 Engine Hanger UPR±Yellow: 12284±27020
Black: 12284±27030
No.2 Engine Hanger12282±28010Yellow: 12282±27060Black: 12282±27070
Bolt91512±6102091642±81025
Torque:
AZ Series:
38 N
m (390 kgf
cm, 28 ft
lbf)
1CD±FTV:
37 N
m (375 kgf
cm, 27 ft
lbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other parts.
20. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Remove the 4 bolts and separate the center member.
(b) Remove the bolt and the 3 nuts, separate the engine mounting insulator RR from the crossmember sub±assy.
(c) Using a transmission jack, support the crossmember
sub±assy.
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C94598
C94596
A
BB
B
LH:
C94597
A
BB
B
RH:
C94595
D29969
A
B
A
B
±
POWER STEERING RACK & PINION POWER STEERING GEAR ASSY
51±43
AVENSIS REPAIR MANUAL (RM1018E)
43. INSTALL FRONT SUSPENSION CROSSMEMBER
SUB±ASSY
(a) Using a transmission jack, support the crossmember
sub±assy w/power steering gear assy.
(b) Install the 2 stopper front onto the crossmember sub± assy.
(c) Install the crossmember sub±assy with the 2 nuts.
Torque: 133 N
m (1,356 kgf
cm, 98 ft
lbf)
(d) Install the stopper rear onto the crossmember bracket LH.
(e) Install the crossmember bracket LH with the 4 bolts. Torque:
Bolt A: 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
(f) Install the stopper rear onto the crossmember bracket RH.
(g) Install the crossmember bracket RH with the 4 bolts. Torque:
Bolt A: 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B: 80 N
m (816 kgf
cm, 59 ft
lbf)
(h) Install the engine mounting insulator RR to the cross- member sub±assy with the bolt and the 3 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
(i) Install the center member with the 4 bolts. Torque:
Bolt A: 45 N
m (459 kgf
cm, 33 ft
lbf)
Bolt B: 52 N
m (530 kgf
cm, 38 ft
lbf)
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730EZ±03
I34799
±
THEFT DETERRENT & DOOR LOCKTRANSMITTER SUB±ASSY MODULE SET DOOR
CONTROL73±19
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1.INSPECT TRANSMITTER SUB±ASSY MODULE SET DOOR CONTROL
(a)Inspect operation of the transmitter.
(1)Remove the battery (lithium battery) from the transmitter (See page 73±17).
(2)Install a new or normal battery (lithium battery).
HINT:
When a new or normal battery is not available, connect 2 new
1.5 V batteries in a series, connect the battery positive (+) to the
battery receptacle side terminal and battery negative (±) to the
bottom terminal, then apply 3 V of voltage to the transmitter.
(3)In a location that is approx. 1 m (3.28 ft) away from the driver side ou\
tside door handle in the right direction, point the key plate of the transmitter at the vehicle and che\
ck operation of the transmit-
ter by pressing the transmission switch on the transmitter body.
Standard:
The door lock can be operated via the remote control.
The LED lights up more than once.
HINT:

The minimum operational distance differs, depending on the operator, the way the transmitter is held,
and the location.

Since the transmitter uses faint electric waves, the operational distanc\
e might be shortened if noise
or strong electric wave occurs in the area where the frequency is used.
(4)Install the battery (lithium battery).
(b)Inspect the battery capacity.
HINT:

The capacity of the battery can be determined only when the battery is inst\
alled in the transmitter. For
a lithium battery used in the transmitter, a voltage of more than 2.5 V is shown on the tester until the
energy is completely consumed, while no battery is installed in the transmitte\
r. Therefore, it is neces-
sary to measure the voltage while the battery is installed in the transmitte\
r (a resistance of 1.2 kis
applied to the battery) when checking the amount of energy left in the \
battery.

If the transmitter is faulty, the amount of energy left in the battery might not be checked correctl\
y.
(1)Remove the battery (lithium battery) from the transmitter (See page 73±17).
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I34797
Lead
I34798
73±20±
THEFT DETERRENT & DOOR LOCK TRANSMITTER SUB±ASSY MODULE SET DOOR
CONTROL
AVENSIS REPAIR MANUAL (RM1018E)
(2) Connect the lead to the negative (±) terminal of the transmitter and install the battery.
(3) Connect the tester positive (+) probe to the (+) bat- tery (lithium battery) and the tester negative (±)
probe to the lead respectively.
(4) Press one of the transmission switches on the transmitter for approx. 1 second.
(5) Press the transmission switch on the transmitter
again to check the voltage.
Standard: 2.2 V or higher
HINT:

When the temperature of the battery is low, the inspection can not be made correctly.
When the outcome of the test is less than 2.2 V, conduct the test again after leaving the battery in a
place with a temperature of 18
C (64F) for more than 30 minutes.

The automatic power±off function causes the voltage of the battery to be 2.5 V or more (a vol\
tage with
no resistance applied to the battery) when 0.8 seconds have passed after \
the switch is pressed. There-
fore, make sure to read the voltage just after the switch is pressed.

Because high voltage might be shown once or twice after the battery returns to \
the specified tempera-
ture, the inspection should be made with the voltage shown after the swi\
tch is pressed at least 3 times.
(6) Disconnect the lead.
(7) Set the battery (lithium battery) in the transmitter.
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AVENSIS (EWD526E)9
B
The
”Current Flow Chart” section, describes which parts each power source (fuses, fusible links\
, and circuit breakers)
transmits current to. In the Power Source circuit diagram, the condition\
s when battery power is supplied to each system
are explained. Since all System Circuit diagrams start from the power so\
urce, the power source system must be fully
understood.
ACC
S 2 6
6
5 2
22
Battery 30A AM2
Starter Short Pin
100A ALT
Fusible Link Block
60A ABS10A ECU–B
7.5A DOME
15A EFI
10A HAZARD
20A RADIO NO.1
10A HORN
20A
10A Fuse
Page
214
230
11 2
122 194
187
180
166
210
ABS
Cigarette Lighter
Combination Meter
Key Reminder and Seat Belt Warning
Light Auto Turn Off
Theft Deterrent and Door Lock ControlABS and Traction Control
Cruise Control
Electronically Controlled Transmission
Multiplex Communication System
STOP System
DOME Headlight
Interior Light
3 EA2 1 EA1E 6
E 7
E 7
2
2
2
2 2
2 2
2
INJECTION Relay
STARTER Relay
B
B
B
B–O
1
1 2
23
4
3
4
W–B W–B
B–W
B–W
E 7
E 7 B
B W
1.25B FL MAIN
50A MAIN
7.5A AM2
15A HAZ–RADIO
2
2 2
2
2W
W EB1
EB1
7
6
W–R I 2 I 2 I 2
WW
W
W W
1 1
1 140A DOOR LOCK CB
7.5A DOME
1
W–L
R
1
1
2
43 1
11
1
1 1 1
G
G
W–R
15A TAIL
20A DEFOG
B–Y
84
32Ignition SW I 8
B–Y 1 1P–L
Battery
15A RAD CIG2
TAIL
Relay
Power Source
J POWER SOURCE (Current Flow Chart)
Engine Room R/B (See Page 20)
2
W W
B
B
B
B
B
W–RWW
W
G–W AM2
AM1
IG2
IG1 W
W
The chart below shows the route by which current flows from the battery \
to each electrical source
(Fusible Link, Circuit Breaker, Fuse, etc.) and other parts.
∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.
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∗The titles given inside the components are the names of the terminals (\
terminal codes) and are not treated as being
abbreviations.
AVENSIS (EWD526E) 17
ABBREVIATIONS D
ABBREVIATIONS
The following abbreviations are used in this manual.
A/C = Air Conditioner
A/T = Automatic Transaxle
ABS = Anti–Lock Brake System
CIS = Commonwealth of Independent States
DLC3 = Data Link Connector 3
EC = Electrochromic
ECT = Electronic Control Transmission
ECU = Electronic Control Unit
EFI = Electronic Fuel Injection
EGR = Exhaust Gas Recirculation
EPS = Electric Power Steering
ESA = Electronic Spark Advance
EVAP = Evaporative Emission
HID = High Intensity Discharge
INT = Intermittent
ISC = Idle Speed Control
J/B = Junction Block
L/B = Liftback Type
LH = Left–Hand
LHD = Left–Hand Drive
M/T = Manual Transaxle
PTC = Positive Temperature Coefficient
R/B = Relay Block
RH = Right–Hand
RHD = Right–Hand Drive
S/D = Sedan Type
SRS = Supplemental Restraint System
SW = Switch
TEMP. = Temperature
TRC = Traction Control
VRV = Vacuum Regulating Valve
VSC = Vehicle Stability Control
VSV = Vacuum Switching Valve
VVT = Variable Valve Timing
VVT–i = Variable Valve Timing–intelligent
W/G = Wagon Type
w/ = With
w/o = Without
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256AVENSIS (EWD526E)
Illumination
(
∗ 3 )
W–B
1
4
T
A
G
13
TOUT
G
TRLY INTB
(
∗ 3 )
Integration Relay
14
15
12
J1 6
G–W
(
∗ 1 )
FL MAIN
3. 0W
Battery
120A ALT (
1AZ–FSE, 1AZ–FE )
100A ALT (
1ZZ–FE, 3ZZ–FE )
140A ALT
(
∗ 2 )
B
2
11
2
B–G
2
1
3
5
7. 5A PANEL
TAIL Relay
(∗ 4 )
10A TAIL
Junction
ConnectorA
4B
1
3 4D
1
3
ED1
1
W
( ∗ 2 )
B–G ( ∗ 1 ) B–L
( ∗ 2 )
DB
12
OFF Tail
Head
Light
Control SW
14
16
W–B
DB
19 DJ
9D J
6D M
4
CA
5C I
8
IC2
3
G
Junction
Connector
J3 0 (
A )G
R
( ∗ 3 )
P 5
Combination SWC12
G
W–B
( LHD )
∗
2 : 1CD–FTV
∗
1 : Gasoline
∗ 3 : w/ Daytime Running Light
∗ 4 : w/o Daytime Running Light
∗ 5 : LHD 1CD–FTV, RHD
∗ 6 : LHD Gasoline
∗ 7 : Except Automatic A/C
∗ 8 : 1CD–FTV Power Heater (
Hot Gas Type )
G
DN
1
DA
23
(
∗ 4 )
R
IL : ∗
5
IO : ∗ 6 A
W–B
Power Heater SW
AA
AA
( ∗ 8 )
(
∗ 8 )
AVENSIS (EWD526E) 257
G
Illumination
A
AJ1 7
(
RHD )
W–B
( RHD )
W–B R–W
W–R
(
RHD )
W–R
( LHD )
W–B
A
Junction
Connector
CPU
Tail
IK
7. 5A
DOME
From Power Source System
(
See Page 120 )
6
1
2
W–R
10A
GAUGE1 DB
7
CA
7
CD
6
R–W
B
21 B20 B14
A
17 B
5
BH
C
FC FAF
CCAC
CC(
RHD )
AC
(
LHD )
IP
CA
6
W–B
(LHD )
W–B
(
RHD )
W–B
ILL+
G
1
2
G
W–B
( RHD )
W–B
( LHD )
GND
CJ
1CA 11
CD
9CG 3
CK
6 A/C Control
Assembly
A1 3
(
A )
, A16 (
B )
A
40 (
∗ 7 )
B
13 (
Automatic A/C )
B
23 (
Automatic A/C )
A
21 (
∗ 7 )Glove Box LightG 3
Junction
ConnectorJ1 0 (
A )
, J11 (
B )
, J26 (
C )
G
G
W–B
( LHD )G
( RHD )
W–B Combination Meter
C10
(
A )
, C11 (
B )
A
(
RHD )
W–B
A
Junction
Connector
J1 5
258 AVENSIS (EWD526E)
Illumination
CH
G
W–B
(∗ 9 )
2
3
5
(
∗ 9 )
( w/ Headlight Cleaner )
W–B
3
G
( w/ Headlight Cleaner )
2CJ
G G
2
7
W–B
(w/ VSC )
(
LHD w/ VSC )
W–B G
( w/ Front Window Deicer )
(
w/ Front Window Deicer )
W–B
( LHD ) G
W–B
(
∗ 17 )
W–B
W–B
( RHD )
1
4
8
9
W–B
( RHD )
ILL+
W–B(∗ 17 )
GND
CK
81 CJ 8CJ3CI 3
CJ
5CJ 11 CH 8
CH
10
CD CI
5 2
CI
CE
5
11
(
LHD )
( RHD )
Hazard SWH13TRC Off SWT 9 F20Multi–DisplayM 1Headlight Cleaner SWH16 H15Headlight Beam Level
Control SW
∗
11 : w/ Multi–Display w/o Navigation System (
Map Type )
∗
10 : w/ Navigation System (
Map Type )
∗
9 : w/ Headlight Beam Level Control w/o HID
∗ 13 : w/ Steering SW
∗ 14 : A/T Except 1AZ–FE
∗ 15 : w/ Seat Heater
∗
12 : Power Heater (
Combustion Type )
∗ 16 : w/ Multi–Display
∗ 17 : RHD w/ VSC
G
W–B
TAIL
ILL–
CG
4
Multi–DisplayM 1
(
∗ 11 )
(
∗ 11 )
( ∗ 10 )(
∗10 )
82
10
13
Front Wiper Deicer SW
AVENSIS (EWD526E) 259
J3 0
(
A )
, J31 (
B )Junction
Connector
HA
4CD
9 BS
CH
IJ
S 7Seat Heater SW
F19Rear Window Defogger SW
( RHD )
1 8
4
(
LHD ) G
W–B W–B
( RHD )
(
LHD )
(
LHD )
( RHD )
5
E
ILL+ E
E
E
W–B W–B W–BGGG
GG
W–B
( RHD )
W–B
( RHD )
W–B
( ∗ 17 )
A
IL
(
LHD )
G
G
( ∗ 15 ) (
LHD ∗14 )
( LHD ∗13 )
(LHD )
( ∗ 15 )
W–B
( ∗ 15 )(
∗15 )(
∗15 )
(
∗ 14 )
W–B
J 8 (
A )
, J 9 (
B )
C
C
3
1
6
3
2
W–B
W–B
( RHD )
( ∗ 17 )
W–B E
(
RHD )
( RHD ∗13 )
G
(
RHD ∗14 )
GG
J1 9
G
( RHD )
(
RHD )
W–B
1
5
AAA
Junction Connector
Junction
Connector
10
CH
2
Junction
ConnectorJ3 2
Personal LightP 8
Combination SWC14
B
FB FBFBFAH
DK
6
DA
9 AB
BC
CH
CF
9
12
(
LHD )
( RHD ) G
( ∗ 12 )
W–B
( RHD )
IC1
8
ID1
7
Junction
Connector
J1 6
W–B
( RHD )
A
ECT Pattern
Select SW
E 8
W–B
( ∗ 13 )
ILL+
EAU
(
∗ 16 )
(
∗ 16 )
W–B
( ∗ 13 )
260
AVENSIS (EWD526E)
Illumination
IK
IP
(
LHD ) G
3
2
G G
W–B
J1 7
A
G
W–B
A
G
( ∗ 12 )
(
∗ 12 )
W–B
W–B
4
8
1
4
1
4 ILL+
GND
( RHD )
Junction
Connector
W–B
CA
12
CF
1
CH
7
CI
4
IN
R 4(
A )
, R 7 (
D )Radio and Player Transmission Control SWT 7Remote Controller
(
Navigation )R11Cigarette Lighter
IlluminationC 7 P 5
G
( ∗ 12 )
W–B
( RHD )
∗
12 : Power Heater (
Combustion Type )
BR
W–B
(
LHD )
( RHD )
AA
ILL
GND
∗
13 : w/ Steering SW
W–B
( ∗ 13 ) A
10
D6
GND
A7
W–B
( ∗ 13 )
Junction
ConnectorJ1 5
A
A
W–B
( RHD )
W–B
( LHD ) Power Heater SW
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