air condition TOYOTA AVENSIS 2003 Service Owner's Manual

02±2
±
PREPARATION DIAGNOSTICS
AVENSIS REPAIR MANUAL (RM1018E)
(09083±00150)Test Lead SetAIR CONDITIONING SYSTEM
ABS WITH EBD SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
MULTIPLEX COMMUNICATION
SYSTEM
ENGINE IMMOBILISER SYSTEM
ABS WITH EBD & BA & TRC & VSC
SYSTEM
WIRELESS DOOR LOCK CONTROL
SYSTEM
COMBINATION METER
KEY REMINDER WARNING SYSTEM
POWER DOOR LOCK CONTROL
SYSTEM
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)
09082±00050TOYOTA Electrical Tester SetPOWER DOOR LOCK CONTROL
SYSTEM
(09083±00150)Test Lead SetAIR CONDITIONING SYSTEM
ABS WITH EBD SYSTEM
ELECTRONIC MOTOR POWER
STEERING SYSTEM
MULTIPLEX COMMUNICATION
SYSTEM
ENGINE IMMOBILISER SYSTEM
ABS WITH EBD & BA & TRC & VSC
SYSTEM
WIRELESS DOOR LOCK CONTROL
SYSTEM
COMBINATION METER
KEY REMINDER WARNING SYSTEM
POWER DOOR LOCK CONTROL
SYSTEM
SFI SYSTEM(1AZ±FE)
SFI SYSTEM(1AZ±FSE)
ECD SYSTEM(1CD±FTV)
SFI SYSTEM(1ZZ±FE/3ZZ±FE)
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U241E(1AZ±FSE))
ELECTRONIC CONTROLLED
AUTOMATIC TRANSAXLE
[ECT](U341E)
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022KJ±01
±
PREPARATION HEATER & AIR CONDITIONER
02±47
AVENSIS REPAIR MANUAL (RM1018E)
HEATER & AIR CONDITIONER
PREPARATION
SST
07110±58060Air Conditioner Service Tool SetREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±58060)Refrigerant Drain Service ValveREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±58070)T±JointREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
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02±48
±
PREPARATION HEATER & AIR CONDITIONER
AVENSIS REPAIR MANUAL (RM1018E)
(07117±58080)Quick Disconnect AdapterREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±58090)Quick Disconnect AdapterREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±78050)Refrigerant Charging GaugeREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
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±
PREPARATION HEATER & AIR CONDITIONER
02±49
AVENSIS REPAIR MANUAL (RM1018E)
(07117±88060)Refrigerant Charging HoseREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±88070)Refrigerant Charging HoseREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
(07117±88080)Refrigerant Charging HoseREFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
07117±48130Vacuum Pump (220 V)W/RECEIVER CONDENSER ASSY
07117±48140Vacuum Pump (240 V)W/RECEIVER CONDENSER ASSY
09870±00015A/C Quick Joint Puller No.1AIR CONDITIONING RADIATOR
ASSY
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02±50
±
PREPARATION HEATER & AIR CONDITIONER
AVENSIS REPAIR MANUAL (RM1018E)
09870±00025A/C Quick Joint Puller No.2AIR CONDITIONING RADIATOR
ASSY
09950±50013Puller C SetAIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
(09951±05010)Hanger 150AIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
(09952±05010)Slide ArmAIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
(09953±05020)Center Bolt 150AIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
(09954±05021)Claw No.2AIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
Recomended Tools
09040±00011Hexagon Wrench SetAIR CONDITIONING RADIATOR
ASSY
W/RECEIVER CONDENSER ASSY
(09043±20050)Socket Hexagon Wrench 5AIR CONDITIONING RADIATOR
ASSY
(09043±20100)Socket Hexagon Wrench 10W/RECEIVER CONDENSER ASSY
09041±00030Torx Driver T30AIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
09042±00010Torx Socket T30AIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
09070±20010Moulding RemoverAIR CONDITIONING CONTROL
ASSY
AIR CONDITIONING RADIATOR
ASSY
BLOWER ASSY
09216±00021Belt Tension GaugeV (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
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±
PREPARATION HEATER & AIR CONDITIONER
02±51
AVENSIS REPAIR MANUAL (RM1018E)
95416±00140Gas Leak Detector
(Halogen Leak Detector)
(DENSO Part No.)REFRIGERANT
AIR CONDITIONING RADIATOR
ASSY
W/PULLEY COMPRESSOR
ASSY(1AZ±FE)
W/PULLEY COMPRESSOR
ASSY(1AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(1CD±FTV)
W/PULLEY COMPRESSOR
ASSY(1ZZ±FE)
W/PULLEY COMPRESSOR
ASSY(2AZ±FSE)
W/PULLEY COMPRESSOR
ASSY(3ZZ±FE)
Equipment
Voltmeter
Anmeter
Ohmmeter
Vinyl tape
Hexagon wrench 4 mm (0.15 in.)
Hexagon wrench 14 mm (0.55 in.)
Gas leak detector
Dial indicator with magnetic base
Radiator cap tester
Torque wrench
Lubricant
ItemCapacityClassification
Compressor oil±ND±OIL 8 or equivalent
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031H3±01
03±24
±
SERVICE SPECIFICATIONS COOLING
AVENSIS REPAIR MANUAL (RM1018E)
COOLING
SERVICE DATA
1ZZ±FE/3ZZ±FE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
86 to 90
C (187 to 198
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.6 psi)
Cooling fan
Standard amperage at 20
C (68
F)
8 to 12 A
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2 Between terminals 3 and 4
Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1AZ±FE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
80 to 84
C (176 to 183
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
93 ± 122 kPa (0.95 ± 1.25 kgf/cm2, 13.4 ± 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.2 psi)
Cooling fan
Standard amperage at 20
C (68
F)
Standard amperage (No.2 (With Air Conditioner)) at 20
C (68
F)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2 Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2 Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1AZ±FSE:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
86 to 90
C (187 to 198
F)
10 mm (0.394 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
74 to 103 kPa (0.75 to 1.05 kgf/cm2, 10.7 to 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)
http://vnx.su

±
SERVICE SPECIFICATIONS COOLING
03±25
AVENSIS REPAIR MANUAL (RM1018E)
Cooling fan
Standard amperage at 20

C (68
F)
Standard amperage (No.2 (With Air Conditioner)) at 20
C (68
F)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
5.2 to 8.2 A (M/T) 8.3 to 11.3 (A/T)
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2 Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2 Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
1CD±FTV:
Thermostat
Valve opening temperature
Valve lift at 95
C (203
F)
80 ± 84
C (176 ± 183
F)
8.5 mm (0.33 in.) or more
Radiator cap sub±assy
Standard opening pressure
Minimum opening pressure
93 ± 122 kPa (0.95 ± 1.25 kgf/cm2, 13.4 ± 17.6 psi)
78 kPa (0.8 kgf/cm2, 11.4 psi)
Cooling fan
Standard amperage at 20
C (68
F)
13.2 A
Cooling fan relay
Specified condition Between terminals 1 and 2
Between terminals 3 and 5
Cooling fan relay No.2
Specified condition Between terminals 1 and 2 Between terminals 3 and 4
Between terminals 3 and 5
Cooling fan relay No.3
Specified condition Between terminals 1 and 2 Between terminals 3 and 5
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
Continuity
No continuity
Continuity (Apply battery voltage terminals 1 and 2)
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±
SERVICE SPECIFICATIONSENGINE MECHANICAL
03±17
AVENSIS REPAIR MANUAL (RM1018E) Part Tightenedft
lbf
kgf
cm
N
m
Engine mounting bracket x No, 2 RH x Transverse engine
engine mounting insulatorA
B
52
113530
1,15238
83
Clutch release cylinder x manual transaxleBolt A
Bolt B
Bolt C12
9.0
5.0122 92
5189
80 in.
lbf
44 in.
lbf
Vane pump assy x Timing chain cover4343931
Front suspension arm sub±assy lower No. 1 x Lower ball joint1271,29694
Front stabilizer link assy x Front suspension7475555
Floor panel brace front x Floor3030622
Engine service cover bracket RH x Body w/o Air conditioning
RHD (w/ Air conditioning) steering position type
9.0
9.092
9280 in.
lbf
80 in.
lbf
Cooler bracket x BodyLHD (w/ Air conditioning) steering position type9.09280 in.
lbf
Oil reservoir bracket No. 1 x Body8.08271 in.
lbf
Return tube sub±assy x Frame8.08271 in.
lbf
Radiator reserve tank x sub±assy x body5.05144 in.
lbf
Compressor and magnetic clutch x Cylinder blockw/ Air conditioning2525518
Radiator relay block x Frame5.05144 in.
lbf
Engine cover No. 1 x Cylinder head cover7.07162 in.
lbf
Air cleaner assy x Body5.05144 in.
lbf
Cylinder head x Cylinder block1st
2nd79
Turn 90
806
Turn 90
58
Turn 90

Camshaft timing control valve assy x Cylinder head9.09280 in.
lbf
Camshaft timing gear assy x Camshaft5455140
Camshaft timing sprocket x Camshaft5455140
Camshaft bearing cap No. 1 x Cylinder head3030122
Camshaft bearing cap No. 2 x Cylinder head3030122
Camshaft bearing cap No. 3 x Cylinder head9.09280 in.
lbf
Chain tensioner assy No. 1 x Timing chain cover9.09280 in.
lbf
Chain tensioner plate x Stiffening crankcase assy121229
Oil pump drive sprocket x Oil pump3030122
Chain vibration damper No. 1 x Cylinder head9.09280 in.
lbf
Chain vibration damper No. 1 x Cylinder block9.09280 in.
lbf
Timing chain guide x Cylinder block9.09280 in.
lbf
Chain tensioner slipper x Cylinder block1919414
Timing chain cover (See page 14±139)Bolt A Bolt B
Bolt C Nut9.021
43
9.092
214
438 9280 in.
lbf
15
32
80 in.
lbf
Oil pan x Stiffening crankcase assy9.09280 in.
lbf
Oil pan drain plug x Oil pan2525518
Crankshaft pulley x Crankshaft1701,733125
Cylinder head cover x Cylinder head Bolt A
Bolt B
Bolt C11
14
2111 2
143
2148.0 10
15
1AZ±FSE:
Part TightenedN
mkgf
cmft
lbf
Front wheel RH1031,05076
Drain plug (M/T)4950036
Engine hanger No.1 x Cylinder head3838728
Engine hanger No.2 x Cylinder head3838728
Engine coolant temperature sensor x Cylinder head2020815
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031HH±01
±
SERVICE SPECIFICATIONS HEATER AND AIR CONDITIONING
03±61
AVENSIS REPAIR MANUAL (RM1018E)
HEATER AND AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume Standard:440
30 g (15.51
1.06 oz.)
Belt deflection New belt:
Used belt:11 ± 13 mm (0.43 ± 0.51 in.)
13.5 ± 16.5 mm (0.53 ± 0.64 in.)
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