REPAIR INSTRUCTION PRECAUTION


  1. BASIC REPAIR HINT


    1. HINTS ON OPERATIONS

      A004T3ME01
      1 Attire
      • Always wear a clean uniform.


      • Hat and safety shoes must be worn.

      2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
      3 Safe operation
      • Use wheel chocks to secure the vehicle.

      • When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.

      • When removing or installing heavy parts, such as the engine, transmission, differential, etc., before starting work make sure there are no problems with the equipment that will be used.

      • When working with 2 or more persons, be sure to check safety for one another.

      • If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.

      4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, a gauge, oil and the parts for replacement.
      5 Removal and installation, disassembly and assembly operations
      • Diagnose with a thorough understanding of proper procedures and of the reported problem.


      • Before removing the parts, check the general condition of the assembly and for deformation and damage.


      • When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed.


      • Clean and wash the removed parts if necessary and assemble them after a thorough check.

      6 Removed parts
      • Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.


      • For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual.


      • Retain the removed parts for customer inspection, if requested.

      7* Checks to perform after work is finished
      • Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened.


      • Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle.


      • Check that there are no oil leaks.

      CAUTION:

      *:Be sure to perform these checks properly, no performing these checks properly after finishing work can lead to serious accident or injury.

    2. JACKING UP AND SUPPORTING VEHICLE


      1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

    3. A004MYHE26
      Text in Illustration
      *1 Seal Lock Adhesive

      PRECOATED PARTS


      1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.

      2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.

      3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.

      4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.

    4. GASKETS


      1. When necessary, use a sealer on gaskets to prevent leaks.

    5. BOLTS, NUTS AND SCREWS


      1. Carefully follow all the specifications for tightening torque. Always use a torque wrench.

      2. Make sure that no foreign matter (burrs, paint, etc.) gets trapped under the heads of the bolts and nuts when tightening them.

    6. A004RECE08
      *1 INCORRECT
      *2 CORRECT

      FUSES


      1. When inspecting a fuse, check that the wire of the fuse is not broken.

      2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit.

      3. When a fuse is replaced, a fuse with the same amperage rating must be used.

        Illustration Symbol Part Name Abbreviation
        A004TL6 A004T26 FUSE FUSE
        A004O8V A004SQL MEDIUM CURRENT FUSE M-FUSE
        A004OUO A004RBS HIGH CURRENT FUSE H-FUSE
        A004NTJ A004TRW FUSIBLE LINK FL
        A004SEY A004T89 CIRCUIT BREAKER CB
    7. CLIPS


      1. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

        Tech Tips

        If clips are damaged during a procedure, always replace the clips with new clips.

        Shape (Example) Procedures/Installation
        A004NL0

        Remove clips with a clip remover or pliers.

        A004T7A
        A004OPM

        Remove clips with a clip remover or screwdriver.

        A004TH6
        A004QU8

        Remove clips with a wide scraper to prevent panel damage.

        A004T1D
        A004OHY

        Remove clips by pushing the center pin through and prying out the shell.

        A004N45
        A004MQA

        Remove clips by unscrewing the center pin and prying out the shell.

        A004OTH
        A004SU4

        Remove clips by prying out the pin and then prying out the shell.

        A004S0V
    8. CLAWS


      1. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

        Tech Tips

        If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones.

        Shape (Example) Procedures / Illustration
        A004P5J

        Using a screwdriver, detach the claws and remove the caps or covers.

        A004MNN
        A004SN4

        Using a screwdriver, detach the claws and remove the caps or covers.

        A004TSP
        A004RJ0

        Using a screwdriver, detach the claws and remove the caps or covers.

        A004RPG
    9. HINGE, GUIDE, CLAMP, PIN ETC.


      1. The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below.

        Tech Tips

        If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

        Shape (Example) Procedures / Illustration
        A004O9C

        Disengage the pins by pulling.

        A004NNT
        A004TH0

        Disengage the pins by pulling.

        A004N3O
        A004NCE

        Remove the clamps with pliers.

        A004N4W
        A004T45

        Disengage the pins by pulling.

        A004SBB
    10. REMOVAL AND INSTALLATION OF VACUUM HOSES


      1. A004QGTE07
        *1 INCORRECT
        *2 CORRECT

        To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.

      2. A004SP4

        When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

      3. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.

      4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary.

    11. A004PTGE01

      TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL


      1. A004STVE01

        Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.

        Note

        If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.

      2. FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM

        The AVENSIS is equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following:


        1. Steering pad

        2. Front passenger airbag assembly

        3. Curtain shield airbag assembly

        4. Front seat side airbag assembly

        5. Knee airbag assembly

        6. Seat belt pretensioner

        7. Center airbag sensor assembly

        8. Front airbag sensor

        9. Side airbag sensor

        10. Rear airbag sensor

        CAUTION:


        • Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions.

        • Before starting work, wait at least 90 seconds after the engine switch is turned off and after the cable is disconnected from the negative (-) battery terminal. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the engine switch off and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy).

        • Do not expose SRS parts directly to hot air or flames.

        Note


        • Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal.

        • For minor collisions where SRS parts do not deploy, always inspect the SRS parts.

        • Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during repairs.

        • Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones.

        • Never disassemble or attempt to repair SRS parts.

        • If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one.

        • Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits.

        • Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels.

        • After work on SRS parts is completed, perform the SRS warning light check.

        • When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system.

        • An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure.


        1. SPIRAL CABLE


          1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.

        2. AIRBAG ASSEMBLY


          1. Airbag assembly with pad:

            Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the airbag assembly.

          2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury.

          3. Grease or detergents of any kind should not be applied to the airbag assembly.

          4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

          5. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

          6. When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.

        3. SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER


          1. Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could cause a serious injury.

          2. Never install the seat outer belt on another vehicle.

          3. Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.

          4. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib wiring.

          5. When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the pretensioner in a safe place away from electrical noise.

          6. As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat outer belt.

          7. Grease, detergents, oil or water should not be applied to the seat outer belt.

        4. AIRBAG SENSOR ASSEMBLY


          1. Never reuse an airbag sensor assembly that has been 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 placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate.

          3. Work must be started at least 90 seconds after the engine switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly.

        5. WIRE HARNESS AND CONNECTOR


          1. The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.

      3. PRE-CRASH SAFETY CITY SENSOR

        CAUTION:

        The pre-crash safety city sensor uses lasers to detect preceding vehicles. The pre-crash safety city sensor is classified as a Class 1M laser product according to the IEC 60825-1 standard. These lasers are not harmful to the naked eye. However, it is necessary to observe the following precautions. Failure to do so may result in severe visual impairment, or at worst, loss of eyesight.


        • To avoid hazardous radiation exposure, never attempt to disassemble the pre-crash safety city sensor or perform maintenance procedures that are not described in the repair manual. When disassembled, the pre-crash safety city sensor is classified as a Class 3B laser product according to the IEC 60825-1 standard and poses an eye injury risk.

        • When removing the pre-crash safety city sensor, always disconnect the connector first.

        • When installing the pre-crash safety city sensor, install the pre-crash safety city sensor to the bracket, and then connect the connector.

        • Do not look into the pre-crash safety city sensor using a magnifying glass, microscope or other optical instrument from a distance of 100 mm (3.94 in.) or less.

        A004TJVE04
      4. Text in Illustration
        *1 Laser Classification Label *2 Laser Explanatory Label
        Laser Emission Data
        Maximum average power 45 mW
        Pulse duration 33 ns
        Wavelength 905 nm
        Divergence (horizontal x vertical) 28°x 12°
      5. ELECTRONIC CONTROL


        1. A004O24E35
          Text in Illustration
          *1 Cable
          *2 Negative (-) Battery Terminal

          REMOVAL AND INSTALLATION OF BATTERY CABLE

          Note


          • Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

          • w/ Radio and Display Receiver Assembly:

            After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.


          1. Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits.

          2. When disconnecting the cable, turn the engine switch off and headlight dimmer switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.

          3. Clock settings*, radio settings, audio system memory, DTCs and other data are cleared when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable.

            Tech Tips

            *: w/o Navigation System

          4. Certain systems need to be initialized after disconnecting and reconnecting the cable to the negative (-) battery terminal.

        2. HANDLING OF ELECTRONIC PARTS


          1. A004NMHE12
            *1 INCORRECT

            Do not open the cover or case of an ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.

          2. Do not pull the wires when disconnecting electronic connectors. Pull the connector.

          3. Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.

          4. When cleaning the engine with steam, protect the electronic components, air filter and emissions-related components from water.

          5. Never use an impact wrench to remove or install temperature switches or temperature sensors.

          6. When measuring the resistance of a wire connector, insert the tester probe carefully to prevent the terminals from bending.

      6. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS


        1. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS


          1. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.

          2. Never work in a pit or near a pit as vaporized fuel will collect in those places.

        2. REMOVING AND INSTALLING FUEL SYSTEM PARTS


          1. Prepare a fire extinguisher before starting the operation.

          2. To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.

          3. Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.

          4. Avoid using iron hammers as they may create sparks.

          5. Dispose of fuel-contaminated cloths separately using a fire resistant container.

      7. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS


        1. A004TTK

          If any metal particles enter inlet system parts, they may damage the engine.

        2. When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.

        3. When installing inlet system parts, check that no metal particles have entered the engine or the installed parts.

      8. HANDLING OF HOSE CLAMPS

        A004MZ0E33
        Text in Illustration
        *1 Clamp Track
        *2 Spring Type Clamp

        1. Before removing the hose, check the clamp position so that it can be reinstalled in the same position.

        2. Replace any deformed or dented clamps with new ones.

        3. When reusing a hose, attach the clamp on the clamp track portion of the hose.

        4. For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration.

      9. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS


        1. A004QXM

          Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.

        2. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the section of the applicable components.

        3. Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice versa.

        4. Check that the antenna and feeder are correctly adjusted.

        5. Do not install a high-powered mobile communication system.

      10. WHEN INSPECTING HEADLIGHT


        1. A004N0Z

          When the headlights are illuminated, do not cover the headlights for 3 minutes or more.

          Note


          • When the headlight dimmer switch assembly is set to HEAD, do not touch the high-voltage socket area of the discharge headlight.

          • As the outer lens of the headlight is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.

      11. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY CONTROL (VSC) SYSTEMS

        When testing with a 2-wheel drum tester such as a speedometer tester, a combination speedometer and brake tester, or a chassis dynamometer, or when jacking up the front wheels and turning the wheels, perform the following procedure to enter inspection mode and disable the VSC systems Click here.

        Tech Tips


        • The vehicle may slip unexpectedly out of the dynamometer because of VSC operations.

        • Pressing the VSC OFF switch (for vehicles with a VSC OFF switch) does not disable VSC operation completely.

        CAUTION:

        Secure the vehicle with chains for safety.

        Note

        During VSC OFF mode, the TRC OFF indicator (multi-information display) and VSC OFF indicator light on the combination meter come on.

      12. PRECAUTIONS FOR TOWING VEHICLES EQUIPPED WITH STOP AND START SYSTEM

        Do not tow the vehicle with all 4 wheels on the ground.

        Note

        If the vehicle is towed with all 4 wheels touching the ground, the stop and start system may be damaged.

        Tech Tips

        If the vehicle must be towed with the 4 wheels on the ground, turn the engine switch off and then turn the ignition switch to ON before towing the vehicle.

      13. PRECAUTIONS FOR TOWING FRONT WHEEL DRIVE VEHICLES


        1. Use one of the following methods to tow the vehicle.

        2. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).

          A004N64E74

          Note

          Do not use any towing method other than those shown above.

        3. If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s). This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 30 km/h (19 mph).

          A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.

          Note

          If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with the front wheels on the ground, the transaxle may be damaged.


          1. Emergency towing procedure


            1. Turn the ignition switch to ON.

            2. for Manual Transaxle:

              Depress the brake pedal and move the transmission shift lever to neutral.

            3. for Automatic Transaxle:

              Depress the brake pedal and move the transmission shift lever to N.

            4. Release the parking brake.

            5. Release the brake pedal slowly.

            Note


            • Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.

            • Do not turn off the ignition switch. Turning off the ignition switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.

        4. The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.

          A004OQC

          1. Do not tow the vehicle facing rearward with the front wheels on the ground.

            Note


            • If the vehicle is towed facing rearward with the front wheels on the ground, the drivetrain may overheat and be damaged.

            • In addition, if the vehicle is equipped with the VSC system, the system may apply the brakes to the rotating wheels.

          2. Do not use a sling-type towing method either from the front or rear.

            Note

            If a sling-type tow truck is used, damage may occur to the vehicle body.

      14. IGNITION SWITCH EXPRESSION

        Tech Tips

        The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the table below are used in this section.

        Expression Ignition Switch (position) Engine Switch (condition)
        Ignition Switch off LOCK Off (Lock)
        Ignition Switch ACC ACC On (ACC)
        Ignition Switch ON ON On (IG)
        Engine Start START On (Start)