01−5

INTRODUCTION − REPAIR INSTRUCTION

REPAIR INSTRUCTION
010ST−01

PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS

D31930

S Always wear a clean uniform.

1 Looks
S A hat and safety shoes must be worn.
2 Vehicle protection S Prepare a grille cover, fender cover, seat cover and floor mat before starting repairs.
S When working with 2 or more persons, be sure to check safety for one another.
S When working with the engine running, make sure to provide ventilation for exhaust fumes in the
workshop.
3 Safe operation S 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.
S When jacking up the vehicle, be sure to support the specified location with a safety stand.
S When lifting up the vehicle, use appropriate safety equipment.
Preparation of tools and
4 S Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
measuring gauge
S Diagnose with a thorough understanding of proper procedures and of the reported problem.
S Before removing the parts, check the general condition of the assembly and for deformation and damage.
Removal and installation,
S When the assembly is complicated, take notes. For example, note the total number of electrical connections,
5 disassembly and assem-
bolts, or hoses removed. Add matchmarks to insure re−assembly of components in the original positions.
bly operations
Temporarily mark hoses and their fittings, if needed.
S Clean and wash the removed parts if necessary and assemble them after a thorough check.
S Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the
new parts.
6 Removed parts S For non−reusable parts such as a gasket, O−ring, and self−locking nut, replace them with new ones following
the instructions in this manual.
S Retain the removed parts for customer inspection, if requested.

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(b) 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 (see page 01−19).

(c) 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 anyway, it must be recoated with the spe-
cified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry the part with compressed air.
Z11554 Then apply new seal lock adhesive appropriate to
the bolts and nuts.
NOTICE:
Perform the torque with the lower limit value of the torque
tolerance.
(4) Some seal lock agents harden slowly. You may
have to wait for the seal lock agent to harden.
(d) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.
Medium Current Fuse and High Current (f) FUSES
Fuse Equal Amperage Rating (1) When replacing fuses, be sure that the new fuse
has the correct amperage rating. DO NOT exceed
the rating or use one with a lower rating.

BE1367

Illustration Symbol Part Name Abbreviation

FUSE FUSE

MEDIUM CURRENT FUSE M−FUSE

HIGH CURRENT FUSE H−FUSE

D27353

V35002

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(g) CLIPS
(1) The removal and installation methods of typical clips used in body parts are shown in the table
below.
HINT:
If clips are damaged during a procedure, always replace the damaged clip with a new clip.

Shape (Example) Removal/Installation

Clip

Pliers

Clip Remover

Remove clips from front or rear using clip remover

or pliers.

Protective Tape

Screwdriver

Remove fasteners with a clip remover or screwdriver.

Protective Tape

Scraper

Remove clips with a wide scraper to prevent

panel damage.

D25786

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Shape (Example) Removal/Installation

Removal Installation

Screwdriver
Push

Clip Remover

Remove rivet by pushing the center pin through and prying

out the rivet shell.
Removal Installation

Screwdriver
Push

Clip Remover

Remove rivet by unscrewing the center pin and prying out

the rivet shell.

Removal Installation

Push

Screwdriver

Clip Remover

Small Clip Remover

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

D32182

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(h) REMOVAL AND INSTALLATION OF VACUUM HOSES

INCORRECT CORRECT (1) To disconnect vacuum hoses, pull and twist from
the end of the hose. Do not pull from the middle of
the hose as this may cause damage.

D31750

(2) When disconnecting vacuum hoses, use tags to

identify where they should be reconnected.
(3) After completing the job, double check that the vac-
uum 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. Use a step−down
adapter for adjustment. Once a hose has been
D25064 stretched, it may leak air.

(i) TORQUE WHEN USING TORQUE WRENCH WITH EX-

TENSION TOOL
L1 L2
(1) If SST or an extension tool is combined with the
torque wrench to extend its length, do not tighten
the torque wrench to the specified torque values in
this manual. The resulting torque will be excessive.
(2) Use the formula below to calculate special torque
values for situations where SST or an extension tool
D02612 is combined with the torque wrench.
(3) Formula: T’ = T x L2/(L1 + L2)
T’ Reading of torque wrench {N×m (kgf×cm, ft×lbf)}
L1 L2 T Torque {N×m (kgf×cm, ft×lbf)}
L1 Length of SST or extension tool (cm)
L2 Length of torque wrench (cm)

D01201

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2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS VERSO/PICNIC is equipped with a Supplemental Restraint System (SRS) and seat belt pre-
tensioner.
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing and lead to serious injury.
Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate
properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to
read the following section carefully.
(a) GENERAL NOTICE
(1) As the malfunction symptoms of the SRS are difficult to confirm the Diagnostic Trouble Codes
(DTCs) become the most important source of information when troubleshooting. When trouble-
shooting the SRS, always check the DTCs before disconnecting the battery (see page 05−972).
(2) Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position
and the negative (−) terminal cable is disconnected from the battery.
(The SRS is equipped with a back−up power source. If work is started within 90 seconds after
turning the ignition switch to lock and disconnecting the negative (−) terminal cable from the bat-
tery, the SRS may deploy).
When the negative (−) terminal cable is disconnected from the battery, clock and audio system
memory is erased. Before starting work, make a note of the settings of each memory system.
When work is finished, reset the clock and audio systems as before.
CAUTION:
Never use the back−up power source (battery or other) to try to keep the system memory from being
erased. The back−up power source may inadvertently power the SRS, and cause it to deploy.
(3) In minor collisions where the SRS does not deploy, the horn button assembly (see page 60−17),
instrument panel passenger airbag assembly (see page 60−28 of pub. No. RM864E), front seat
airbag assembly (see page 60−34 of pub. No. RM864E), curtain shield airbag assembly (see
page 60−43 of pub. No. RM864E) and seat belt pretensioner (see page 61−2 of pub. No.
RM864E) should be inspected before further use of the vehicle.
(4) Never use SRS parts from another vehicle. When replacing parts, use new parts.
(5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument
panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly
or seat belt pretensioner.
(7) Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly
or the instrument panel passenger airbag assembly, front seat airbag assembly or curtain shield
airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other
defects in the case, bracket or connector are present.
(8) Do not directly expose the airbag sensor assembly, horn button assembly, instrument panel pas-
senger airbag assembly, front seat airbag assembly, curtain shield airbag assembly or seat belt
pretensioner to hot air or flames.
(9) Use a voltmeter/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting electri-
cal circuits.
(10) Information labels are attached to the SRS components. Follow the instructions on the labels.
(11) After work on the SRS is completed, check the SRS warning lamp (see page 05−972).

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(b) SPIRAL CABLE (in Combination Switch)

(1) The steering wheel must be fitted correctly to the
steering column with the spiral cable in the neutral
position, otherwise cable disconnection and other
problems may occur. Refer to page 60−24 for in-
Mark
formation about correct installation of the steering
wheel.

D30401

(c) HORN BUTTON ASSEMBLY (with Airbag)

(1) When removing the horn button assembly or handling a new horn button, it should be placed with
the pad surface facing up. See the illustration below.
Placing the horn button with the pad surface facing down may lead to a serious accident if the
airbag accidently inflates. Also, do not place anything on top of the horn button.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the steering wheel pad.
(4) Store the horn button assembly in an area where the ambient temperature is below 93˚C
(200˚F), the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag sensor (ECU) con-
nectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility
of the airbag or seat belt pretensioner deploying due to currents entering the squib wiring.
(6) When disposing of the vehicle or the horn button assembly by itself, the airbag should be inflated
using an SST before disposal (see page 60−17). Perform the operation in a safe place away from
electrical noise.
Example:

CORRECT INCORRECT

D25096

Example:

NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER Z13950

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(d) INSTRUMENT PANEL PASSENGER AIRBAG ASSY

(1) Always place a removed or new instrument panel passenger airbag assembly with the airbag
inflation direction facing upward.
Placing the airbag assembly with the airbag inflation direction facing downward could cause a
serious accident if the airbag inflates.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the instrument panel passenger 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 electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(4 pins). 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 a vehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (see page 60−28 of pub. No. RM864E).
Activate in a safe place away from electrical noise.
Example: CORRECT INCORRECT

D27522

Example:

NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER Z13951

(e) CURTAIN SHIELD AIRBAG ASSEMBLY

(1) Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep
it in a safe place.
NOTICE:
Plastic bag is not re−useable.
CAUTION:
Never disassemble the curtain shield airbag assembly.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.

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(4) Store the airbag assembly in an area where the ambient temperature is below 93˚C (200˚F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag sensor (ECU) con-
nectors (2 pins). 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 a vehicle or the curtain shield airbag assembly unit by itself, the airbag should
be deployed using SST before disposal (see page 60−43 of pub. No. RM864E).
Activate in a safe place away from electrical noise.
Example:

CORRECT INCORRECT

Clear Plastic Bag

D31641

NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER D30931

(f) FRONT SEAT AIRBAG ASSEMBLY

(1) Always place a removed or new front seat airbag assembly with the airbag inflation direction fac-
ing up.
Placing the airbag assembly with the airbag inflation direction facing downward could cause a
serious accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease should not be applied to the front seat airbag assembly, and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly in an area where the ambient temperature is below 93˚C (200˚F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). 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 a vehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (see page 60−34 of pub. RM864E).
Activate in a safe place away from electrical noise.

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Example:

NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER D30924

(g) SEAT BELT PRETENSIONER

(1) Never measure the resistance of the seat belt pretensioner. This may cause the seat belt preten-
sioner to activate, which could cause serious injury.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner on another vehicle.
(4) Store the seat belt pretensioner in an area where the ambient temperature is below 80˚C
(176˚F), the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag sensor (ECU) con-
nectors (2 pins). 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 a vehicle or the seat belt pretensioner unit by itself, the seat belt pretensioner
should be activated before disposal (see page 61−2 of pub. RM864E). Activate in a safe place
away from electrical noise.
(7) As the seat belt pretensioner is hot after being activated, allow some time for it to cool down suffi-
ciently before disposal. Never apply water to try to cool down the seat belt pretensioner.
(8) Grease, detergents, oil or water should not be applied to the front seat outer belt.
Example:

NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER D30370

(h) AIRBAG SENSOR ASSEMBLY (ECU)

(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 mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted to the floor, the SRS may activate.
(3) Work must be started at least 90 seconds after the power switch’s power mode is changed to
OFF and the negative (−) terminal cable is disconnected from the battery, even if only loosening
the set bolts of the airbag sensor assembly.
(i) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con-
nectors in the system are a standard yellow color. If the SRS wire harness becomes discon-
nected or the connector becomes broken, repair or replace it.

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3. ELECTRONIC CONTROL
Negative (−)
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
Terminal
NAL
(1) Before performing electronic work, disconnect the
battery negative (−) terminal cable beforehand to
prevent component and wire damage caused by
accidental short circuits.
(2) When disconnecting the terminal cable, turn the
D25080 ignition switch and lighting switch OFF and loosen
the terminal nut completely. Perform these opera-
tions without twisting or prying the terminal. Re-
move the battery cable from the battery post.
(3) Clock settings, radio settings, DTCs and other data
are erased when the battery cable is removed. Be-
fore removing the battery cable, record any neces-
sary data.
(b) HANDLING OF ELECTRONIC 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 rendered inoperative by
static electricity.
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
INCORRECT
(3) Be careful not to drop electronic components, such
D31751 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 emission−re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the resistance of a wire connector,
insert the tester probe carefully to prevent terminals
from bending.

4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS

(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation that does not have welders, grinders, drills, electric mo-
tors, stoves, or any other ignition sources.
(2) Never work in a pit or near a pit as vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operation.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray the area with water. The work surface will become slippery. Do not clean up spills with
water as this will spread and gasoline and 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 speaks.
(5) Dispose of fuel−contaminated shop rags separately using a fire resistant container.

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5. REMOVAL AND INSTALLATION OF ENGINE INTAKE

PARTS
(a) If any metal particle enters the inlet pass, this may dam-
age the engine.
(b) When removing and installing the inlet system parts, cov-
er the openings of the removed parts and engine open-
ings. Use clean shop rags, gummed tape, or other suit-
able materials.
D01563 (c) When installing the inlet system parts, check that no metal
particles have entered the engine or the installed part.
Spring Type Clamp
6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so
that it can be reinstalled in the same position.
(b) Replace deformed or dented clamps with a new one.
(c) When reusing a hose, attach the clamp on the clamp track
portion of the hose.
(d) For a spring type clamp, you may want to spread the tabs
Clamp Track slightly after installation by pushing in the direction of the
D25081 arrow marks as shown in the illustration.

7. FOR VEHICLES EQUIPPED WITH MOBILE COMMU-

NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors
of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away
from the ECU and sensors of the vehicle electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on applicable components.
D20025 (c) Keep the antenna and feeder separate from other wirings
as much as possible. This will prevent signals from the
communication equipment from affecting vehicle equip-
ment and vice−versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install high−powered mobile communication sys-
tems.

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8. FOR VEHICLES EQUIPPED WITH TRACTION CON-

TROL (TRC) SYSTEM
When testing with a 2−wheel drum tester such as a speedome-
ter tester, a combination tester of the speedometer and brake,
a chassis dynamometer, or when jacking up the front wheels
and driving the wheels, always turn the TRC system OFF be-
forehand via the TRC OFF switch before testing.
NOTICE:
TRC system OFF condition can be confirmed by the ”TRC
OFF” warning indicator light in the combination meter.
TRC OFF Indicator Light (a) Confirm that the TRC system is OFF
(1) Press the TRC cut (”TRC OFF”) switch to turn off the
TRC system.
(2) Check if the TRC OFF indicator light illuminates.
HINT:
The SLIP indicator light should always operate right after the
engine is restarted.
(3) Begin testing.
TRC Cut Switch
B78848

(4) Press the TRC cut switch to turn on the TRC system
and check that the TRC OFF indicator light turns off.
HINT:
The SLIP indicator light blinks when the TRC system is operat-
ing.

SLIP Indicator Light

B78847

9. FOR VEHICLES EQUIPPED WITH VEHICLE SKID

DLC3
CONTROL (VSC) SYSTEM
CG (a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, disable the Vehicle Skid
1 2 3 4 5 6 7 8 Control system (VSC). To disable the VSC, turn the
ignition switch OFF and connect SST to terminals
9 10 11 12 1314 1516 12 (TS) and 4 (CG) of DLC3.
SST 09843−18040
TS A82779 NOTICE:
S Confirm that the VSC warning light blinks.
S VSC system will be reset when the engine is re-
started.
S For safety, secure the vehicle with restraint chains
while using a wheel dynamometer.

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(b) NOTICES OF RELATED OPERATIONS TO VSC

(1) Do not carry out unnecessary installation and re-
moval as it might affect the adjustment of VSC re-
lated parts.
(2) Be sure to follow the instructions for work prepara-
tion and final confirmation of proper operation of the
VSC system.

10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

CAUTION:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause ove-
heating and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the converter.

AVENSIS VERSO/PICNIC Supplement (RM1032E)