oil capacity TOYOTA AVENSIS 2002 Repair Manual

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)

550Z2±01
I35326
I35327
I35328
55±78
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
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±185)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±185)
6.REMOVE ENGINE UNDER COVER RH (See page 14±185)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±185) 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)

I35333
I35333
(1)(2)
(3)
(4)
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
55±87
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
11. 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)
NOTICE:

When checking the compressor oil level, observe the precautions on the cooler removal/inst\
al-
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.
12. 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.
13. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
14. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55±46)
15. FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)

550Z0±01
I35323
I35324
I35325
55±74
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1ZZ±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±5)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±5)
6.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±5)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 3 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)

550YY±01
I35323
I35324
I35325
55±70
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (3ZZ±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±5)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±5)
6.REMOVE ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±5)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 3 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)

170FW±01
A56222
A56223
17±12
± LUBRICATIONOIL FILTER SUB±ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or sol-
vents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
4. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp. qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK

170FV±01
A56222
A56223
± LUBRICATIONOIL FILTER SUB±ASSY (1AZ±FSE)
17±19
AVENSIS REPAIR MANUAL (RM1018E)
OIL FILTER SUB±ASSY (1AZ±FSE)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains po-
tentially harmful contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and frequency of contact of your skin to used
oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use
water±less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or sol-
vents.

In order to preserve the environment, used oil and used oil filter must be disposed of only at
designated disposal sites.
1. REMOVE ENGINE UNDER COVER RH
2. DRAIN ENGINE OIL
(a) Install a new gasket and drain plug after draining engine oil.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
3. REMOVE OIL FILTER SUB±ASSY
(a) Using SST, remove the oil filter.
SST 09228±06501
4. INSTALL OIL FILTER SUB±ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228±06501
5. ADD ENGINE OIL
(a) Fill with fresh engine oil.
Capacity:
Drain and refill w/ Oil filter change 4.2 liters (4.4 US qts, 3.7 lmp. qts)
Drain and refill w/o Oil filter change 4.0 liters (4.2 US qts, 3.5 lmp. qts)
Dry fill 4.9 liters (5.2 US qts, 4.3 lmp. qts)
(b) Install the oil filler cap.
6. INSPECT OIL LEAK

± LUBRICATIONOIL FILTER SUB±ASSY (1CD±FTV)
17±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Fill with fresh engine oil.
Capacity:
With the oil filter replacement: 5.9 liters (6.2 US qts, 5.2 lmp. qts)
Without the oil filter replacement: 5.3 liters (5.6 US qts, 4.7 lmp. qts)
Dry fill: 6.7 liters (7.1 US qts, 5.9 lmp. qts)
(c) Install the oil filler cap.
5. CHECK FOR ENGINE OIL LEAKS

± LUBRICATIONOIL FILTER SUB±ASSY (1ZZ±FE/3ZZ±FE)
17±5
AVENSIS REPAIR MANUAL (RM1018E)
4. INSTALL OIL PAN DRAIN PLUG
(a) Clean and install the oil pan drain plug with a new gasket.
Torque: 37 N
m (377 kgf
cm, 27 in.
lbf)
5. ADD ENGINE OIL
Capacity:
With oil filler replacement: 3.7 liters (3.9 US qts, 3.3 lmp. qts)
Without oil filler replacement: 3.5 liters (3.7 US qts, 3.1 lmp. qts)
Dry fill: 4.2 liters (4.4 US qts, 3.7 lmp. qts)
6. CHECK FOR ENGINE OIL LEAKS

D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±4
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 9.9
0.3 mm (0.390
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)