TOYOTA AVENSIS 2002 Repair Manual

I34977
N
m (kgf
cm, ft
lbf) : Specified torqueCooler Refrigerant Suction Hose No.1
Liquid Tube Sub±assy A
Cooler Refrigerant Discharge Hose No.1
5.4 (55, 47 in.
lbf)
5.4 (55, 47 in.
lbf)
9.8 (100, 87 in.
lbf)
LHD:
1AZ±FSE:
9.8 (100, 87 in.
lbf)
1AZ±FE:
9.8 (100, 87 in.
lbf)
± HEATER & AIR CONDITIONERREFRIGERANT LINE
55±41
AVENSIS REPAIR MANUAL (RM1018E)

I34978
N
m (kgf
cm, ft
lbf) : Specified torqueCooler Refrigerant Suction Hose No.1
Liquid Tube Sub±assy A Cooler Refrigerant Discharge Hose No.1
9.8 (100, 87 in.
lbf)
RHD:
1AZ±FSE:
5.4 (55, 47 in.
lbf)
5.4 (55, 47 in.
lbf)
1AZ±FE: 55±42
± HEATER & AIR CONDITIONERREFRIGERANT LINE
AVENSIS REPAIR MANUAL (RM1018E)

I34979
N
m (kgf
cm, ft
lbf) : Specified torqueCooler Refrigerant Suction Hose No.1
Liquid Tube Sub±assy A
Cooler Refrigerant Discharge Hose No.1
5.4 (55, 47 in.
lbf)
5.4 (55, 47 in.
lbf)
9.8 (100, 87 in.
lbf)
LHD:
1CD±FTV:
w/o Hot Gas Heater:
9.8 (100, 87 in.
lbf)
Suction Servic Valve
9.8 (100, 87 in.
lbf)
± HEATER & AIR CONDITIONERREFRIGERANT LINE
55±43
AVENSIS REPAIR MANUAL (RM1018E)

I34980N
m (kgf
cm, ft
lbf) : Specified torque Liquid Tube Sub±assy A
Cooler Refrigerant Discharge Hose No.1
9.8 (100, 87 in.
lbf)
LHD:
1CD±FTV:
w/ Hot Gas Heater:
Suction Servic Valve
5.4 (55, 47 in.
lbf)
9.8 (100, 87 in.
lbf)
9.8 (100, 87 in.
lbf)
9.8 (100, 87 in.
lbf)
5.4 (55, 47 in.
lbf)
Discharge Tube Sub±assy
9.8 (100, 87 in.
lbf)
Cooler Refrigerant Suction Hose No.1
55±44
± HEATER & AIR CONDITIONERREFRIGERANT LINE
AVENSIS REPAIR MANUAL (RM1018E)

I34981
N
m (kgf
cm, ft
lbf) : Specified torque Liquid Tube Sub±assy B
RHD:
1CD±FTV:
w/ Hot Gas Heater:
5.4 (55, 47 in.
lbf)
9.8 (100, 87 in.
lbf)
5.4 (55, 47 in.
lbf)
Discharge Tube Sub±assy
5.4 (55, 47 in.
lbf)
9.8 (100, 87 in.
lbf)
Cooler Refrigerant Discharge Hose No.1
9.8 (100, 87 in.
lbf)
9.8 (100, 87 in.
lbf)
Liquid Tube Sub±assy A
Cooler Refrigerant Suction Hose No.1
13 (132, 9.5)
± HEATER & AIR CONDITIONERREFRIGERANT LINE
55±45
AVENSIS REPAIR MANUAL (RM1018E)

550YP±01
I31981
Bolt B
Nut A
I31981
I31981
Bolt B
Nut A
Measuring
Position
F11928
CORRECT WRONG WRONG 55±46
± HEATER & AIR CONDITIONERV (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.1
AVENSIS REPAIR MANUAL (RM1018E)
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY)
BELT NO.1
REPLACEMENT
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE ROOM COVER SIDE
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Loosen the nut A.
(b) Loosen the bolt B and remove the V (cooler compressor
to crankshaft pulley) belt No. 1.
5. INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Temporarily install a new V (cooler compressor to crank-
shaft pulley) belt No. 1 as shown in the illustration.
6. ADJUST V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Tighten the nut A.
Torque: 2.5 N
m (25 kgf
cm, 22 ft
lbf)
(b) Apply drive belt tension by turning bolt B.
Belt deflection:
New belt: 11 ± 13 mm (0.43 ± 0.51 in.)
Used belt: 13.5 ± 16.5 mm (0.53 ± 0.64 in.)
HINT:

The new belt refers to a belt which is used for less than
5 minutes on the running engine.

The used belt refers to a belt which is used for 5 minutes,
or more on the running engine.

After installing the drive belt, check that the belt fits prop-
erly in the ribbed grooves.

Check that the drive belt does not slip off the groove at the
end of the pulley by hand.

I31981
Nut A
± HEATER & AIR CONDITIONERV (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.155±47
AVENSIS REPAIR MANUAL (RM1018E)
7. FULLY TIGHTEN V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Tighten the nut A.
Torque: 39 N
m (390 kgf
cm, 29 ft
lbf)

550Z3±01
I37058
Pulley
Weight Hub
Weight Hub
± HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (1AZ±FE)
55±81
AVENSIS REPAIR MANUAL (RM1018E)
W/PULLEY COMPRESSOR ASSY (1AZ±FE)
ON±VEHICLE INSPECTION
1. INSPECT W/PULLEY COMPRESSOR ASSY
(a) Check the operation.
(1) Start the engine.
(2) Inspect the weight hub.
Standard: The weight hub rotates along with the pulley

550Z4±01
I35326
I35327
I35328
55±82
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38) SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. DISCONNECT COOLER REFRIGERANT SUCTIONHOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the w/pulley compressor assy.
(b) Remove the O±ring from the cooler refrigerant suction hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
3. DISCONNECT COOLER REFRIGERANT DISCHARGE
HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/pulley compressor assy.
(b) Remove the O±ring from the cooler refrigerant discharge
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±105)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±105)
6.REMOVE ENGINE UNDER COVER RH (See page 14±105)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010 8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
9. INSPECT COMPRESSOR OIL
(a) When replacing the w/pulley compressor assy with a new one, after gradually \
removing the refrigerant gas from the service valve, drain the following amount of oil from the new w\
/pulley compressor assy
before installation.
Standard:
(Oil capacity inside new w/pulley compressor assy: 90 + 15 cc (3.0 + 0.5 fl. oz.) ) ± (Remaining
oil amount in the removed w/pulley compressor assy) = (Oil amount to be r\
emoved when replac-
ing)

I35328
(1)(2)
(3)
(4)
I35327
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
55±83
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

When checking the compressor oil level, observe the precautions on the c\
ooler removal/instal-
lation.

Since compressor oil remains in the pipes of the vehicle, if a new w/pulley c\
ompressor assy
is installed without removing some oil inside, the oil amount becomes ex\
cessive, preventing
heat exchange in the refrigerant cycle and causing refrigerant failure.

If the remaining oil in the removed w/pulley compressor assy is too smal\
l in volume, check for
oil leakage.

Be sure to use ND±OIL 8 for compressor oil.
10. INSTALL W/PULLEY COMPRESSOR ASSY
(a) Install the w/pulley compressor assy with the 4 bolts.Torque: 29 N
m (300 kgf
cm, 21 ft
lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to
install the w/pulley compressor assy.
(b) Connect the connector.
11.INSTALL FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010
12. INSTALL COOLER REFRIGERANT DISCHARGEHOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant discharge hose No.1.
(d) Install the cooler refrigerant discharge hose No.1 on the w/pulley compressor assy with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
13. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant suction hose
No.1.