2003 TOYOTA AVENSIS ECO mode

010BK±01
01±12
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE±J1930 terms and abbreviations used in this ma\
nual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )±±ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal±
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection±
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position±
CTOXContinuous Trap Oxidizer±
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition±
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode±
ECLEngine Control Level±
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control±
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory±
FEPROMFlash Erasable Programmable Read Only Memory±
FFFlexible Fuel±
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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2600P±03
F44620
G21679
26±26
±
FRONT SUSPENSION STABILIZER BAR FRONT
AVENSIS REPAIR MANUAL (RM1018E)
STABILIZER BAR FRONT
REPLACEMENT
HINT:
COMPONENTS: See page 26±2
1. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH
(a) Remove the 2 nuts and front stabilizer link assy LH.
HINT:
If the ball joint turns together with the nut,use a hexagon wrench
(6 mm) to hold the stud.
3. REMOVE FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side. 4. INSPECT FRONT STABILIZER LINK ASSY LH
(a) As shown in the illustration, flip the ball joint stud back andforth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate
of 3 ± 5 seconds per 1 turn and take the torque reading
on the 5th turn.
Turning torque:
0.05 ± 1.96 N´m (0.5 ± 20 kgf´cm, 0.4 ± 17 in.´lbf)
5.SEPARATE TIE ROD END SUB±ASSY LH (See page 30±6) SST 09628±62011
6. SEPARATE TIE ROD END SUB±ASSY RH
SST 09628±62011
HINT:
Separate the RH side by the same procedures as the LH side.
7.SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (See page 30±6)
8. SEPARATE FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH
HINT:
Separate the RH side by the same procedures as the LH side.
9. SEPARATE RACK & PINION POWER STEERING GEAR ASSY
(a)Electric power steering model: See page 51±28
(b)Oil pressure power steering model: See page 51±36
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320VW±01
F45949
32±56
±
BRAKE BRAKE ACTUATOR ASSY (W/ VSC)
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/ VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake \
pedal cannot be de- pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously\
. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously\
. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
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320VY±01
F45949
±
BRAKE BRAKE ACTUATOR ASSY (W/O VSC)
32±53
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/O VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake \
pedal cannot be de- pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously\
. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously\
. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
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± 50 g (± 1.76 oz.)
I37057
0.1 (1.0)0.4 (4.0)
0.3 (3.0)
0.2 (2.0) MPa (kgf/cm
2)
Pressure on low pressure side
Outside temperature
0
C ( F)
15 (59) 20 (68)
30 (86)
25 (77) 35 (95)
0 g (0 oz.)
(Standard)
+ 50 g (+ 1.76 oz.)
±
HEATER & AIR CONDITIONER REFRIGERANT
55±31
AVENSIS REPAIR MANUAL (RM1018E)
3. w/ Hot gas heater:
INSPECT REFRIGERANT VOLUME
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the the manifold gauge pres-
sure when these conditions are established.
Test conditions:

Engine is at idle.

Blower speed control switch is at ºHIº.

Temperature control dial is at ºMAX. COOLº.

Engine has been warmed up.

All doors are fully open.

Hood is fully open.

Air inlet mode selector damper is at RECIRE.

Air outlet damper is at FACE.

Outside temperature is 15 ± 35
C (59± 95

F).
(b) Check refrigerant volume according to the graph below.
RangeAmount of refrigerantCorrective actions
Except range belowInsufficient or excessive
Supply refrigerant until low
pressure become within the standard
50 g
(
1.76 oz.), or remove
refrigerant and then sup- ply proper amount of re-
frigerant
Standard
50 g
(
1.76 oz.)Proper±
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600K8±01
H42769
60±68
±
SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG SENSOR REAR LH
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replacement procedure of the RH side is the same as that for the LH side.
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE REAR DOOR SCUFF PLATE LH (See page 76±36)
4.REMOVE REAR SEAT CUSHION ASSEMBLY (SEDAN MODELS) (See page 76±36)
5.REMOVE REAR SIDE SEAT BACK ASSY LH (See page 76±36) 6. REMOVE AIR BAG SENSOR REAR LH
(a) Disconnect the connector of the airbag sensor rear LH.
(b) Remove the 2 bolts and the airbag sensor rear LH.
7.INSTALL AIR BAG SENSOR REAR LH (See page 60±11)
(a) Check that the ignition switch is off.
(b) Check that the battery negative (±) terminal is disconnected.
NOTICE:
Do not start the operation for 90 seconds after removing the terminal.
(c) Install the airbag sensor rear LH with the 2 bolts. Torque: 8.0 N
m (82 kgf
cm, 70 ft
lbf)
NOTICE:

If the airbag sensor rear LH has been dropped, or there are any cracks, \
dents or other defects
in the case, bracket or connector, replace the airbag sensor rear LH with a new one.

When installing the airbag sensor rear LH, take care that the SRS wiring does not interfere \
with
other parts and is not pinched between other parts.
(d) Connect the connector of the airbag sensor rear LH.
(e) Check that no play is identified.
8.INSPECT SRS WARNING LIGHT (See page 05±1184)
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E68116
±
WIPER & WASHER WIPER AND WASHER SYSTEM
66±5
AVENSIS REPAIR MANUAL (RM1018E)
5. WINDSHIELD WIPER RELAY ASSY
(a) Check voltage of each terminal of the connector
Standard:
Tester connectionConditionSpecified voltage
1 (+B) ± Body groundIgnition switch OFF
ON0
10 to 14 V
2 (RSI) ± Body groundRain sensor is covered by handSignal waveform
4 (WF) ± Body groundFront washer switch OFF
ON10 to 14 V
0 V
8 (+2) ± Body groundFront wiper is in high speed operation
(When front wiper switch is in AUTO position)10 to 14 V
9 (F1) ± Body groundFront wiper switch OFF
AUTO10 to 14 V
0 V
11 (F2) ± Body groundFront wiper switch OFF
AUTO0
10 to 14 V
12 (WF) ± Body groundFront washer switch OFF
ON10 to 14 V
0 V
16 (+1) ± Body groundFront wiper is in 10 speed operation
(when front wiper switch is in AUTO position)10 to 14 V
17 (+S) ± Body groundAlwaysBelow 1 V
19 (SP) ± Body groundIgnition switch OFF
ON0 V
10 to 14 V
20 (VR1) ± Body groundIgnition switch OFF
ON0 V
10 to 14 V
22 (E) ± Body groundAlwaysBelow 1 V
23 (SG) ± Body groundAlwaysBelow 1 V
24 (VP2) ± Body groundIgnition switch is ON and rain sensor adjust
switch is in (+) position
(±) positionSignal waveform
6. AUTO WIPER SYSTEM OPERATION CHECK
(a) Spray once at the area where the rain sensor is placed, then the wiper blades\
immediately will carry
out a wiping cycle. If the water is continuos sprayed to the rain sensor ar\
ea of the windscreen, the wiper
blades first should carry out interval mode, then change to low speed an\
d finally reach high speed after
a few seconds.
By stopping spraying water to the screen the wiper blade changing back t\
heir speed until they stop
wiping.
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BO4421
Adhesive
Adhesive
BO4420Body
B67821
Primer M
Primer M
AdhesiveCORRECT
WRONG
: Primer M
70±36
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
5. CLEAN BACK DOOR GLASS
(a) Clean the outer circumference of the glass with white gas- oline.
NOTICE:

Do not touch the glass surface after cleaning it.

Be careful not to damage the body.
6. INSTALL BACK DOOR GLASS
(a) Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on thecontact surface of the body to ensure the appropri-
ate surface shape.
HINT:
Leave as much adhesive on the body as possible.
(2) Clean the contact surface of the body with a pieceof shop rag saturated with cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
(b) Using a brush, coat the exposed part of the body on the
vehicle side with Primer M.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not coat the adhesive with Primer M.

Do not keep any of the opened Primer M for later use.
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