Toyota AVENSIS 2000 Betriebsanleitung

2000 TOYOTA MOTOR CORPORATION

duced or copied, in whole or in part, without the

written permission of Toyota Motor Corporation.

First Printing: May 17, 2000 01–000517–00

FOREWORD

This supplement has been prepared to provide information covering general service repairs for the chassis

and body of the TOYOTA AVENSIS/CORONA which underwent changes in July, 2000.

Applicable models: ZZT220, 221 series

AZT220 series

ST220 series

CDT220 series

For the service specifications and repair procedures of the above model other than those listed in this supple-

ment, refer to the following manuals.

ManualName Pub. No.

SAVENSIS/CORONA Chassis and Body Repair Manual RM599E

SAVENSIS/CORONA Chassis and Body Repair Manual Supplement (Aug., 1999) RM698E

S1ZZ–FE, 3ZZ–FE Engine Repair Manual RM782E

S1AZ–FSE Engine Repair Manual RM783E

S3S–FE Engine Repair Manual RM395E

S3S–FE Engine Repair Manual Supplement (Jan., 1996) RM495E

S3S–FE Engine Repair Manual Supplement (Oct., 1997) RM609E

S1CD–FTV Engine Repair Manual RM697E

SA245E Automatic Transaxle Repair Manual RM757E

SU240E Automatic Transaxle Repair Manual RM740U

SAVENSIS/CORONA Electrical Wiring Diagram EWD330Y

SAVENSIS/CORONA Electrical Wiring Diagram Supplement (May, 1999) EWD373F

SAVENSIS/CORONA Electrical Wiring Diagram Supplement (Jul., 2000) EWD418F

SAVENSIS/CORONA New Car Features NCF145E

SAVENSIS/CORONA New Car Features Supplement NCF168E

STOYOTA Model New Car Features Supplement NCF195E

All information in this manual is based on the latest product information at the time of publication. However,

specifications and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

CAUTION

This manual does not include all the necessary items about repair and service. This manual is made

for the purpose of the use for the persons who have special techniques and certifications. In the

cases that non–specialized or uncertified technicians perform repair or service only using this manu-

al or without proper equipment or tool, that may cause severe injury to you or other people around

and also cause damage to your customer’s vehicle.

In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow

the instruction shown below.

SMust read this manual thoroughly. It is especially important to have good understanding all the

contents written in the PRECAUTION of ”IN” section.

SThe service method written in this manual is very effective to perform repair and service. When

performing the operations following the procedures using this manual, be sure to use tools spe-

cified and recommended. If using non–specified or recommended tools and service method,

be sure to confirm safety of the technicians and any possibility of causing personal injury or

damage to the customer’s vehicle before starting the operation.

SIf part replacement is necessary, must replace the part with the same part number or equivalent

part. Do not replace it with inferior quality.

SIt is important to note that this manual contains various ”Cautions” and ”Notices” that must be

carefully observed in order to reduce the risk of personal injury during service or repair, or the

possibility that improper service or repair may damage the vehicle or render it unsafe. It is also

important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is

important to warn of all the possible hazardous consequences that might result from failure to

follow these instructions.

INTRODUCTION

PREPARATION

SERVICE SPECIFICATIONS

DIAGNOSTICS

CLUTCH

C50, C250 MANUAL TRANSAXLE

E351 MANUAL TRANSAXLE

S54, S55 MANUAL TRANSAXLE

A246E AUTOMATIC TRANSAXLE

U240E AUTOMATIC TRANSAXLE

SUSPENSION AND AXLE

BRAKE

STEERING

BODY ELECTRICAL

BODY

AIR CONDITIONING

ALPHABETICAL INDEX

INTRODUCTION

HOW TO USE THIS MANUAL IN–1. . . . . . . . . . . . .

GENERAL INFORMATION IN–1. . . . . . . . . . . . . . . . . .

IDENTIFICATION INFORMATION IN–3. . . . . . . . . .

VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER IN–3. . . . . . . . . . . . . . . .

REPAIR INSTRUCTIONS IN–4. . . . . . . . . . . . . . . . .

GENERAL INFORMATION IN–4. . . . . . . . . . . . . . . . . .

VEHICLE LIFT AND

SUPPORT LOCATIONS IN–7. . . . . . . . . . . . . . . . . .

FOR ALL OF VEHICLES IN–9. . . . . . . . . . . . . . . . . .

PRECAUTION IN–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO TROUBLESHOOT

ECU CONTROLLED SYSTEMS IN–19. . . . . . . . .

GENERAL INFORMATION IN–19. . . . . . . . . . . . . . . . . .

HOW TO PROCEED WITH

TROUBLESHOOTING IN–20. . . . . . . . . . . . . . . . . . . .

HOW TO USE THE DIAGNOSTIC CHART

AND INSPECTION PROCEDURE IN–30. . . . . . . . . .

TERMS IN–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS USED IN THIS MANUAL IN–35. . . .

IN00U–65

N17080

Filler Cap

Float

Reservoir Tank

zGrommet

Clip

Slotted Spring Pin

: Specified torque

zNon–reusable part

Cylinder

Piston

Push Rod

Washer

Snap Ring

Boot

zGasket

Lock Nut

Clevis Pin

Clevis

N·m (kgf·cm, ft·lbf)

12 (120, 9)

15(155, 11)

–INTRODUCTION HOW TO USE THIS MANUAL

IN–1

AVENSIS/CORONA SUP (RM781E)

HOW TO USE THIS MANUAL

GENERAL INFORMATION

1. INDEX

An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you

in finding your way through the manual, the section title and major heading are given at the top of every page.

2. PRECAUTION

At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained

in that section.

Read these precautions before starting any repair task.

3. TROUBLESHOOTING

TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the

cause. The fundamentals of how to proceed with troubleshooting are described on page IN–20.

Be sure to read this before performing troubleshooting.

4. PREPARATION

Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-

cial Service Materials) which should be prepared before beginning the operation and explains the purpose

of each one.

5. REPAIR PROCEDURES

Most repair operations begin with an overview illustration. It identifies the components and shows how the

parts fit together.

Example:

Illustration:

what to do and where

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a)

Task heading : what to do

SST 09350–30020 (09350–06120)

Set part No. Component part No.

Detailed text : how to do task

(b)

Piston stroke: 1.40 Ċ1.70 mm (0.0551 Ċ 0.0669 in.)

Specification

Place SST and a dial indicator onto the overdrive brake pis-

ton as shown in the illustration.

Measure the stroke applying and releasing the compressed

air (392 Ċ 785 kPa, 4 Ċ 8 kgf/cm2or 57 Ċ114 psi) as shown

in the illustration.

IN–2

–INTRODUCTION HOW TO USE THIS MANUAL

AVENSIS/CORONA SUP (RM781E)

The procedures are presented in a step–by–step format:

SThe illustration shows what to do and where to do it.

SThe task heading tells what to do.

SThe detailed text tells how to perform the task and gives other information such as specifications

and warnings.

Exampleȧ

This format provides the experienced technician with a FAST TRACK to the information needed. The upper

case task heading can be read at a glance when necessary, and the text below it provides detailed informa-

tion. Important specifications and warnings always stand out in bold type.

6. REFERENCES

References have been kept to a minimum. However, when they are required you are given the page to refer

to.

7. SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the

procedure to look up your specifications. They are also found in Service Specifications section for quick ref-

erence.

8. CAUTIONS, NOTICES, HINTS:

SCAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other

people.

SNOTICES are also presented in bold type, and indicate the possibility of damage to the components

being repaired.

SHINTS are separated from the text but do not appear in bold. They provide additional information to

help you perform the repair efficiently.

9. SI UNIT

The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of

Unit), and alternately expressed in the metric system and in the English System.

Example:

Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

IN06B–11

B02393

B12481

1AZ–FSE engine:

3S–FE engine: 1CD–FTV engine:

1ZZ–FE, 3ZZ–FE engines:

–INTRODUCTION IDENTIFICATION INFORMATION

IN–3

AVENSIS/CORONA SUP (RM781E)

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER

1. VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped in the engine

compartment. This number has also been stamped on the

manufacturer’s label.

A: Vehicle Identification Number

B: Manufacturer’s Label

2. ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block, as

shown in the illustration.

FI1066

IN03Z–03

IN–4

–INTRODUCTION REPAIR INSTRUCTIONS

AVENSIS/CORONA SUP (RM781E)

REPAIR INSTRUCTIONS

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.

(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.

BE1367

Medium Current Fuse and High Current Fuse

Equal Amperage Rating

V00076

Abbreviation

Part Name

SymbolIllustration

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

CIRCUIT BREAKER

FUSE

M–FUSE

H–FUSE

–INTRODUCTION REPAIR INSTRUCTIONS

IN–5

AVENSIS/CORONA SUP (RM781E)

(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.

(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.

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