low oil pressure TOYOTA AVENSIS 2003 Service Service Manual

D31004
Inscribed Mark
R08702
Vernier Calipers
F08480
SST(s)
Oil Seal

D30334
Vinyl Tape
±
POWER STEERING VANE PUMP ASSY (AZ Series)
51±13
AVENSIS REPAIR MANUAL (RM1018E)
If necessary, replace the flow control valve assy with the one
having the same letter as inscribed on the housing sub±assy
front.
Inscribed mark: A, B, C, D, E or F
HINT:
There are 6 different marks for flow control valve assy.
MarkPart number
A44330±05130
B44330±05140
C44330±05150
D44330±05160
E44330±05170
F44330±05180
21. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
(a) Using vernier calipers, measure the free length of the compression spring.
Minimum free length: 36.9 mm ( 1.453 in.)
If it is less than the minimum, replace the compression spring.
22. INSPECT PRESSURE PORT UNION SUB±ASSY
(a) If the union seat in the pressure port union sub±assy is remarkably damaged, it may cause flui\
d leak- age. Replace the pressure port union sub±assy.
23. INSTALL VANE PUMP HOUSING OIL SEAL
(a) Coat a new housing oil seal lip with power steering fluid.
(b) Using SST(s) and a press, install a new housing oil seal.SST 09950±60010 (09951±00280), 09950±70010
(09951±07100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
24. INSTALL W/PULLEY SHAFT SUB±ASSY
(a) Coat inside bushing surface of the housing sub±assy front with power steering fluid.
(b) Gradually insert the w/pulley shaft sub±assy.
NOTICE:
Do not damage the oil seal lip.
HINT:
Tape the shaft before inserting.
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F42475
F40330
A
SST(s)
BFulcrum Length
F41596
Pressure Feed
Tube Assy
Stopper
51±16
±
POWER STEERING VANE PUMP ASSY (AZ Series)
AVENSIS REPAIR MANUAL (RM1018E)
32. INSTALL FLOW CONTROL VALVE ASSY
(a) Coat the compression spring and the flow control valve assy with power steering fluid.
(b) Install the compression spring and the flow control valve assy.
(c) Coat a new O±ring with power steering fluid and install it onto the pressure port union sub±assy.
(d) Install the pressure port union sub±assy. Torque: 69 N
m (704 kgf
cm, 51 ft
lbf)
33. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O±ring with power steering fluid, and install it to the su\
ction port union.
(b) Install the suction port union with the bolt. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
34. INSTALL PUMP BRACKET REAR
(a) Install the vane pump bracket rear with the bolt. Torque: 44 N
m (449 kgf
cm, 32 ft
lbf)
HINT:
Make sure that the stopper of the bracket touches the vane pump body, then torque the bolt.
35. INSTALL VANE PUMP ASSY
(a) Temporarily tighten the bolt A to the vane pump assy.
(b) Install the vane pump assy and the bolt B.Torque: 37 N
m (377 kgf
cm, 27 ft
lbf)
(c) Using SST(s) and a deep socket (14 mm), tighten the bolt
A.
SST 09249±63010
Torque: 26 N
m (264 kgf
cm, 19 ft
lbf)
HINT:

Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).

This torque value is effective when SST(s) is parallel to a
torque wrench.
(d) Connect the connector to the oil pressure switch.
36. CONNECT PRESSURE FEED TUBE ASSY
(a) Install the pressure feed tube assy and gasket to the vane pump assy with the union bolt.
HINT:
Make sure the stopper of the pressure feed tube assy touches
the pump housing front as shown in the illustration.
(b) Using a spanner (27 mm) to hold the pressure port union, torque the union bolt.
Torque: 52 N
m (525 kgf
cm, 38 ft
lbf)
(c) Install the pressure feed tube assy with bolt to the pump bracket rear.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
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5507E±03
AC2810
AC2811
N11084
Wrong Okay
HI
LO
HILO
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
55±1
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cold water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a hospital or see a physician for profes- sional treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant system, oil lu-
brication will be insufficient and compressor may burnout may
occur, so take care to avoid this, necessary care should be tak-
en.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING
Open and close the only low pressure valve. If the high pressure
valves are opened, refrigerant flows in the reverse direction and
cause the charging cylinder to rupture.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating, etc.
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I22122
Condition: Air conditioning system does not function.NOTE : These gauge indica-
tions occur when the refrigera-
tion system opens and the re-
frigerant is charged without
vacuuming.
I22123
Condition: Air conditioning system does not function effectively.
±
HEATER & AIR CONDITIONER REFRIGERANT
55±29
AVENSIS REPAIR MANUAL (RM1018E)
(7) When there is air in the refrigeration system:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and the high pressure
sides

The low pressure piping is too
hot to touch

RHD AZ engine series:
Bubbles can be seen through sight
glass
Air in refrigeration system

There is air in refrigeration sys-
tem

Vacuuming is insufficient
(1) Check it compressor oil is dirty
or insufficient
(2) Vacuum and supply new refrig-
erant
(8) When the expansion valve malfunctions:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and high pressure sides

Frost or dew is on piping on low
pressure side
Trouble with expansion valve

Excessive refrigerant in low
pressure piping

Expansion valve opened too
wide
Replace expansion valve
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I22122
ConditionNOTE : These gauge indica-
tions occur when the refrigera-
tion system opens and the re-
frigerant is charged without
vacuuming.
: Air conditioning system does not function.
I22123
Condition : Air conditioning system does not function effectively.
55±36
±
HEATER & AIR CONDITIONER REFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(7) When there is air in the refrigeration system:
SymptomProbable causeDiagnosisCorrective Actions
Pressure is extreamly high on both
low and the high pressure sidesAir in refrigeration system

There is air in refrigeration sys-
tem

Vacuuming is insufficient(1) Check if compressor oil is dirty
or insufficient
(2) Vacuum air and supply new re-
frigerant
(8) When the refrigerant filter is defective:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
low pressure side

Pressure is extreamly high on
high pressure side
Trouble with refrigerant filterExcessive refrigerantReplace refrigerant filter
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550Z8±01


I37091
Over charged
Mean
value
in proper
range
Hight
Pressure
Refrigerant Amount
30 g (
1.06 oz.)
Amount to be charged
Sub±cool system
RHD AZ Engine series:
55±38
±
HEATER & AIR CONDITIONER REFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Turn the A/C switch ON.
(b) Operate the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 min\
uites to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compresso\
r as
much as possible.
(c) Shut off the engine.
(d) Let the refrigerant gas out.
SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. CHARGE REFRIGERANT
(a) Using a vacuum pump, perform vacuuming.
(b) Charge refrigerant, HFC±134a (R134a).
Standard: 440
30 g (15.51
1.06 oz.)
SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
3. WARM UP ENGINE
4. INSPECT LEAKAGE OF REFRIGERANT
(a) Using a gas leak detector, check for leakage of the refrigerant.
NOTICE:
1CD±FTV Hot gas heater:
Since the system uses a refrigerant filter (fixed valve), sound of the refr\
igerant circulation (hissing
sound) can be heard for approx. 30 seconds after turning the A/C off. T\
his is merely a sound of bal-
ancing the low pressure with the high pressure, not a sound of abnormality.
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710CM±02
±
INSTRUMENT PANEL/METERCOMBINATION METER
71±1
AVENSIS REPAIR MANUAL (RM1018E)
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Discharge warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Brake warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
ABS warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
SRS warning light does not come on.
1.Wire Harness or Connector
2.Airbag Sensor Assy
3.Combination Meter Assy±
05±1197 ±
Open Door warning light does not come on.
1.Wire Harness or Connector
2.Front Door Courtesy Light
3.Body ECU
4.Combination Meter Assy±
±
±
±
Fuel Level warning light does not come on.
1.Wire Harness or Connector
2.Fuel Sender Gauge
3.Combination Meter Assy±
±
±
Low Oil Pressure warning light does not come on.
1.Wire Harness or Connector
2.Low Oil Pressure Warning Switch
3.Combination Meter Assy±
±
±
Engine Oil Level warning light does not come on.
1.Wire Harness or Connector
2.Oil Level Sensor
3.Combination Meter Assy±
±
±
Belt warning light does not come on.
1.Wire Harness or Connector
2.Body ECU
3.Front Inner Belt Assy
4.Combination Meter Assy±
±
05±1522
±
VSC warning light does not come on.
1.Wire Harness or Connector
2.VSC Circuit
3.Combination Meter Assy±
05±752 ±
Indicator Lights:
SymptomSuspect AreaSee page
Shift indicator light do not come on.
1. Wire Harness or Connector
2. ECM
3. Neutral Start Switch Circuit
4. Combination Meter Assy±
±
±
±
Turn indicator light does not come on.
1. Wire Harness or Connector
2. Turn Signal and Hazard Warning System
3. Combination Meter Assy±
65±9 ±
Glow indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy±
±
±
TRC off indicator light does not come on.
1. Wire Harness or Connector
2. VSC Circuit
3. Combination Meter Assy±
05±752 ±
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IG
SPEED
BKL SW
(D±seat)
BKL SW
(P seat)
WRN LAMP
BUZZERON
OFF
15km/h
0
BELT ON
BELT OFF
LVL1
LVL2 BELT ON
BELT OFF
ON
OFF OFF
30s
90s30s90s
±
INSTRUMENT PANEL/METER COMBINATION METER
71±5
AVENSIS REPAIR MANUAL (RM1018E)
7. INSPECT SEAT BELT WARNING LIGHT & BUZZER
(a) Check the operation.
(1) Turn the ignition switch to ON and check that the warning light comes on.\
(2) Fasten the outer belt to the inner belt and check that the warning light\
goes out.
(3) Disconnect the connector from the buckle switch and ground the terminal \
on the wire harness
side connector.
(4) Turn the ignition switch to ON and check that the warning light comes on.\
8. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Inspect the circuit. (1) Disconnect the connector from the low oil pressure switch.
(2) Turn the ignition switch to ON.
(3) Ground the terminal of the wire harness side connector, then check the low oil pressure warninglight.
Low oil pressure warning light: Come on
9. INSPECT BRAKE WARNING LIGHT
(a) Inspect the parking brake warning light.
(1) Disconnect the connector from the parking brake switch and ground the terminal on the wire har-ness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
(b) Inspect the brake fluid level warning light.
(1) Disconnect the connector from the brake fluid level warning switch and c\
onnect the terminalson the wire harness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
10. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Inspect the continuity.
(1) Remove the reservoir tank cap and strainer.
(2) Disconnect the connector.
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38AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1AZ–FSE]
A5
F6
C6
A10
H2
H6
F11
F9
(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
E4
A6
A4
E5
F5
B1
H1
H5
E2
F7
F8
H9C2H10F16H7C1H8B3B2F13F12
H12A12A3C3A11H3F4H4H11A1A2E1A9F3F1
C5
(A/T)
(*1)
(*2)
(M/T)
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 2 Brake Booster Pressure Sensor
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 5 Counter Gear Speed Sensor
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
E 4 Electronic Driver Unit
E 5 Electronic Driver Unit
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH
F 3 Front Fog Light LH F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
F 16 Fuel Pressure Sensor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 7 Heated Oxygen Sensor (Bank 1 Sensor 1)
H 8 Heated Oxygen Sensor (Bank 1 Sensor 2)
H 9 Heated Oxygen Sensor (Bank 2 Sensor 1)
H 10 Heated Oxygen Sensor (Bank 2 Sensor 2)
H 11 Horn LH
H 12 Horn RH
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40AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1AZ
–FE]
A5
F6
C6
A10
H2
H6
F11
F9(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
F5
A6
A4
B1
H1
E2
H5
F7
F8
A8C2H10A7C1H8B3F13F12
H12A12A3C3A11H3F4H4H11A1A2E1A9F3F1
C5
(A/T)
(*1)
(*2)
(M/T)
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 7 Air Fuel Ratio Sensor (Bank 1 Sensor 1)
A 8 Air Fuel Ratio Sensor (Bank 2 Sensor 1)
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 5 Counter Gear Speed Sensor
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH F 3 Front Fog Light LH
F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 8 Heated Oxygen Sensor (Bank 1 Sensor 2)
H 10 Heated Oxygen Sensor (Bank 2 Sensor 2)
H 11 Horn LH
H 12 Horn RH
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