Get INTRODUCTION -> Repair Instructions Guide for Toyota Avensis 4 Door First Generation (1997-2003)

IN–4

INTRODUCTION

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REPAIR INSTRUCTIONS

IN03Z–03

GENERAL INFORMATION

BASIC REPAIR HINT

(a) Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.

(b) During disassembly, keep parts in the appropriate order

to facilitate reassembly.

(1) Before performing electrical work, disconnect the

negative (–) terminal cable from the battery.

(2) If it is necessary to disconnect the battery for in-

spection or repair, first disconnect the negative (–)

terminal.

FI1066

(3) When disconnecting the terminal cable, to prevent

damage to the battery terminal, loosen the cable

nut and raise the cable straight up without twisting

or prying it.

(4) Clean the battery terminals and cable ends with a

clean shop rag. Do not scrape them with a file or oth-

er abrasive objects.

(5) Install the cable ends to the battery terminals after

loosening the nut and tighten the nut after installa-

tion. Do not use a hammer to tap the cable ends

onto the terminals.

(6) Be sure the cover for the positive (+) terminal is

properly in place.

(d) Check hose and wiring connectors to make sure that they

are connected securely and correctly.

(e) Non–reusable parts

(1) Always replace cotter pins, gaskets, O–rings and oil

seals, etc. with new ones.

(2) Non–reusable parts are indicated in the component

illustrations by the ”z” symbol.

(f)

Precoated parts

Precoated parts are bolts and nuts, etc. that are coated

with a seal lock adhesive at the factory.

(1) If a precoated part is retightened, loosened or

caused to move in any way, it must be recoated with

the specified adhesive.

(2) When reusing precoated parts, clean off the old

adhesive and dry with compressed air. Then apply

the specified seal lock adhesive to the bolt, nut or

threads.

(3) Precoated parts are indicated in the component il-

lustrations by the ”L” symbol.

(g) When necessary, use a sealer on gaskets to prevent

leaks.

AVENSIS/CORONA SUP (RM781E)

IN–5

INTRODUCTION

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REPAIR INSTRUCTIONS

(h) Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.

(i)

Use of special service tools (SST) and special service ma-

terials (SSM) may be required, depending on the nature

of the repair. Be sure to use SST and SSM where speci-

fied and follow the proper work procedure. A list of SST

and SSM can be found in Preparation section in this

manual.

(j)

When replacing fuses, be sure the new fuse has the cor-

rect amperage rating. DO NOT exceed the rating or use

one with a lower rating.

Medium Current Fuse and High Current Fuse

EqualAmperageRating

BE1367

Illustration

Symbol

Part Name

Abbreviation

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

M–FUSE

H–FUSE

CIRCUIT BREAKER

V00076

(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop-

er locations (See page IN–7).

(1) If the vehicle is to be jacked up only at the front or

rear end, make sure to place the stopper under the

wheels at the opposite end to block them in order to

ensure safety.

AVENSIS/CORONA SUP (RM781E)

IN–6

INTRODUCTION

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REPAIR INSTRUCTIONS

(2) After the vehicle is jacked up, be sure to support it

on stands. It is extremely dangerous to do any work

on a vehicle raised on a jack alone, even for a small

job that can be finished quickly.

(l)

Observe the following precautions to avoid damage to the

following parts:

(1) Do not open the cover or case of the ECU unless

absolutely necessary. (If the IC terminals are

touched, the IC may be destroyed by static electric-

ity.)

(2) To disconnect vacuum hoses, pull off the end, not

the middle of the hose.

WRONG

CORRECT

(3) To pull apart electrical connectors, pull on the con-

nector itself, not the wires.

(4) Be careful not to drop electrical components, such

as sensors or relays. If they are dropped on a hard

floor, they should be replaced and not reused.

(5) When steam cleaning an engine, protect the elec-

tronic components, air filter and emission–related

components from water.

IN0253

(6) Never use an impact wrench to remove or install

temperature switches or temperature sensors.

(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals

from bending.

WRONG

CORRECT

(8) When using a vacuum gauge, never force the hose

onto a connector that is too large. Use a step–down

adapter for adjustment. Once the hose has been

stretched, it may leak air.

IN0252

(m) Installation and removal of vacuum hose:

(1) When disconnecting vacuum hoses, use tags to

identify where they should be reconnected to.

(2) After completing a job, double check that the vacu-

um hoses are properly connected. A label under the

hood shows the proper layout.

Example

(n) Unless otherwise stated, all resistance is measured at an

ambient temperature of 20°C (68°F). Because the resis-

tance may be outside specifications if measured at high

temperatures immediately after the vehicle has been run-

ning, measurement should be made when the engine has

cooled down.

IN0002

AVENSIS/CORONA SUP (RM781E)

INTRODUCTION -> Repair Instructions for Your Toyota Avensis 4 Door First Generation (1997-2003)

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