TOYOTA AVENSIS 2003 Service Repair Manual

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.
http://vnx.su

I35326
55±84
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the cooler refrigerant suction hose No.1 on the w/ pulley compressor assy with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
14.CHARGE REFRIGERANT (See page 55±38) SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050,
07117±88060, 07117±88070, 07117±88080)
15.WARM UP ENGINE (See page 55±38)
16.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)
http://vnx.su

550Z1±01
I37058
Pulley
Weight HubWeight Hub
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
55±77
AVENSIS REPAIR MANUAL (RM1018E)
W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
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
http://vnx.su

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)
http://vnx.su

I35328
(1)(2)
(3)
(4)
I35327
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
55±79
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±185) 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.
http://vnx.su

I35326
55±80
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the cooler refrigerant suction hose No.1 on the w/ pulley compressor assy with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
14.CHARGE REFRIGERANT (See page 55±38) SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050,
07117±88060, 07117±88070, 07117±88080)
Specified amount: 440
30 g (15.51
1.06 oz.)
15.WARM UP ENGINE (See page 55±38)
16.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)
http://vnx.su

550Z5±01
I37059
PulleyWeight HubWeight Hub
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
55±85
AVENSIS REPAIR MANUAL (RM1018E)
W/PULLEY COMPRESSOR ASSY (1CD±FTV)
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
http://vnx.su

550Z6±01
I35329
I35330
I35331
I35332
55±86
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
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 (LHD STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the suction servic valve.
(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. REMOVE SUCTION SERVIC VALVE (LHD STEERING
POSITION TYPE)
(a) Remove the 2 bolts and disconnect the suction service valve from the w/pulley compressor assy.
(b) Remove the O±ring from the suction service valve.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4. DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1 (RHD STEERING POSITION TYPE)
(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.
5. 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.
6. REMOVE RADIATOR SUPPORT OPENING COVER
7. REMOVE ENGINE ROOM COVER SIDE
8. REMOVE ENGINE UNDER COVER RH
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
http://vnx.su

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)
http://vnx.su

I35332
I35330
I35331
55±88
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
16. INSTALL COOLER REFRIGERANT DISCHARGE 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 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)
17. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (RHD STEERING POSITION TYPE)
(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.
(d) Install the cooler refrigerant suction hose No.1 on the w/ pulley compressor assy with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
18. INSTALL SUCTION SERVIC VALVE (LHD STEERING
POSITION TYPE)
(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 suction service valve.
(d) Install the suction servic valve on the w/pulley compres- sor assy with the 2 bolts.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
19. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE)
(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.
http://vnx.su