air conditioning TOYOTA AVENSIS 2005 Service Repair Manual

A79150
A09671
A84294
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)14 −121
AVENSIS Supplement (RM1045E)
104. REMOVE INTAKE MANIFOLD INSULATOR NO.1
(a) Remove the 2 bolts and intake manifold insulator.
105. REMOVE COMMON RAIL ASSY (See page 11 −67)
106. REMOVE INTAKE MANIFOLD
(a) Remove the 8 bolts and 2 nuts, then remove the intake manifold and gasket.
107. REMOVE INJECTION PUMP DRIVE PULLEY (See page 11 −58)
SST 09960 −10010 (09962 −01000, 09963 −01000)
108. REMOVE TIMING BELT NO.3 COVER
(a) Remove the 2 bolts and 2 seal washers, then remove the timing belt cover.
109. REMOVE OIL LEVEL GAGE GUIDE (See page 17 −11 )
110. REMOVE INJECTION PUMP STAY NO.1 (See page 11 −58)
111. REMOVE INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
112. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
(a) Remove the 4 bolts and compressor mounting bracket.
113. REMOVE WATER INLET (See Pub. No. RM1018E on page 16 −50)
114. REMOVE THERMOSTAT
115. REMOVE OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, remove the union bolt,oil cooler pipe and gasket.

A84380
A84378
14−122−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
116. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE
(a) Remove the 3 bolts and fuel pipe.
117. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the bolt and crankshaft position sensor.
118. REMOVE CAMSHAFT POSITION SENSOR
(a) Remove the bolt and camshaft position sensor. 119. REM O VE ENG I NE CO O L ANT TEM PERAT URESENSOR
120. REPLACE PARTIAL ENGINE ASSY
121. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Torque: 20 N
m (200 kgf
cm, 14 ft
lbf)
122. INSTALL CAMSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
123. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
124. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE
Torque:
8.8 N
m (90 kgf
cm, 78 in.
lbf) for M6
21 N
m (209 kgf
cm, 15 ft
lbf) for M8
125. INSTALL OIL COOLER PIPE
(a) Using a socket wrench for 27 mm, install 2 new gaskets and the oil cooler pipe with the union bolt. Torque: 56 N
m (575 kgf
cm, 42 ft
lbf)
126. INSTALL THERMOSTAT (See Pub. No. RM1018E on page 16 −50)
127. INSTALL WATER INLET (See Pub. No. RM1018E on page 16 −50)
128. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONING)
Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
129. INSTALL INJECTION OR SUPPLY PUMP ASSY (See page 11 −58)
130. INSTALL INJECTION PUMP STAY NO.1 (See page 11 −58)
131. INSTALL OIL LEVEL GAGE GUIDE (See page 17 −11 )
132. INSTALL TIMING BELT NO.3 COVER Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

A93403
2to7mm
(0.0787 to
0.2756 in.)0to4mm
(0 to
0.1575 in.)
Intake Shutter Side:
Air Hose No. 3 Side:
4to12mm
(0.1575 to
0.4724 in.)
14
−132
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
191. INSTALL FRONT AXLE ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
192. INSTALL FRONT SUSPENSION ARM SUB −ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
193. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2
(See Pub. No. RM1018E on page 51 −36)
194. INSTALL FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
195. INSTALL TIE ROD END SUB −ASSY LH (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
196. INSTALL FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30 −6)
HINT:
Perform the same procedure as above on the opposite side.
197. INSTALL RETURN TUBE SUB −ASSY
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
198. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
199. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
200. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 55 −86)
201. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See Pub. No. RM1018E on page 14 −269)
202. INSTALL CLUTCH RELEASE CYLINDER ASSY (See Pub. No. RM1018E on page 42 −17)
203. INSTALL CLUTCH ACCUMULATOR ASSY (See Pub. No. RM1018E on page 42 −22)
SST 09023 −00100
204. INSTALL AIR TUBE NO.2
(a) Install the air hose and 2 hose clamps as shown in the il-lustration.

A87967
Upward90_
Clamp
Bolt
Turbocharger Side:
Air Hose No. 2 Side:
Front 90
_ Clamp Bolt
20.4_
14
−134
−
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD −FTV)(From September,
2003)
AVENSIS Supplement (RM1045E)
(b) Tighten the 2 hose clamps as shown in the illustration. Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
(c) Install the air tube No. 1 with the 3 bolts and nut. Torque: 25 N
m (255 kgf
cm, 18 ft
lbf)
208. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSY Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
209. INSTALL RADIATOR ASSY (W/ AIR CONDITIONING) (See Pub. No. RM1018E on page 16 −51)
210. INSTALL ENGINE ROOM RELAY BLOCK NO.3
Torque: 5.3 N
m (54 kgf
cm, 47 in.
lbf)
211. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)
212. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
213. INSTALL BATTERY Torque:
5.0 N
m (51 kgf
cm, 44 in.
lbf) for bolt
3.0 to 4.0 N
m (31 to 41 kgf
cm, 27 to 35 in.
lbf) for nut
5.4 N
m (55 kgf
cm, 48 in.
lbf) for terminal
214. INSTALL ENGINE COVER SUB −ASSY NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
215. BLEED CLUTCH PIPE LINE (See Pub. No. RM1018E on page 42 −12)
216. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
217. ADD MANUAL TRANSAXLE OIL (See Pub. No. RM1018E on page 41 −5)
218. ADD ENGINE OIL (See Pub. No. RM1018E on page 17 −30)
219. ADD ENGINE COOLANT (See page 16 −19)
220. CHECK CLUTCH FLUID LEAKAGE
221. CHECK FLUID LEVEL IN RESERVOIR
222. CHECK BRAKE FLUID LEAKAGE
223. CHECK FOR ENGINE OIL LEAKS
224. CHECK FOR FUEL LEAKS (See page 11 −46)
225. CHECK FOR ENGINE COOLANT LEAKS (See page 16 −15)
226. CHECK FOR EXHAUST GAS LEAKS
227. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See Pub. No. RM1018E on page 26 −6)

A61173
B A
TA C
A52006
A09593
SST
(Attachment) 14−88
− ENGINE MECHANICALENGINE (1CD−FTV)(From September, 2003)
AVENSIS Supplement (RM1045E)
(b) Inspect the generator V−ribbed belt.
(1) Check that the tension indicator is within range A on
the auto tensioner scale.
If the tension indicator is not within range A, replace the belt with
a new one.
HINT:
When replacing the drive belt with a new one, the tension indi-
cator should be within range B.
6. INSPECT ENGINE IDLE SPEED
(a) Using SST, connect a tachometer test probe to terminal
9 (TAC) of the DLC3.
SST 09843−18040
(b) Check the idle speed.
Idle speed: 750 to 850 rpm
NOTICE:
SCheck the idle speed with the cooling fan OFF.
SSwitch OFF all accessories and air conditioning be-
fore connecting the test probe to the terminal.
7. INSPECT MAXIMUM SPEED
(a) Start the engine.
(b) Fully depress the accelerator pedal.
(c) Check the maximum speed.
Maximum speed: 5,100 to 5,250 rpm
8. INSPECT COMPRESSION
(a) Warm up the engine to the normal operating temperature,
then stop the engine.
(b) Remove the 4 glow plugs
(see Pub. No. RM1018E on page 19−33).
(c) Disconnect the 4 injector connectors.
(d) Inspect the cylinder compression pressure.
(1) Install SST (an attachment) to the glow plug hole.
SST 09992−00025 (09992−00121, 09992−00211)
Torque: 12 N
m (125 kgf
cm, 95 ft
lbf)

A79320
(f)
(e)
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A60622
14–12– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(e) Remove the bolt, then disconnect the ground terminal.
(f) Disconnect the ground terminal connector.
(g) Remove the nut and disconnect battery terminal B.
38. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V–ribbed belt tensioner clockwise slowly and
loosen it. Then, remove the fan and generator V belt and
put back the V–ribbed belt tensioner carefully.
39. REMOVE GENERATOR ASSY (See Pub. No. RM1018E on page 19–7)
40. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
Secure the compressor and hoses off to the side instead of discharging the A/C system.
1ZZ–FE (See Pub. No. RM1018E on page 55–74)
3ZZ–FE (See Pub. No. RM1018E on page 55–70)
41. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and column hole cover silencer sheet.
42. SEPARATE STEERING INTERMEDIATE SHAFT (See Pub. No. RM1018E on page 50–9)
43. REMOVE FRONT DOOR SCUFF PLATE RH (See Pub. No. RM1018E on page 71–11)
44. REMOVE COWL SIDE TRIM BOARD RH (See Pub. No. RM1018E on page 71–11)
45. REMOVE FRONT FLOOR FOOTREST (RHD STEERING POSITION TYPE)
46. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts and floor panel brace front.
47. REMOVE EXHAUST PIPE ASSY FRONT (See Pub. No. RM1018E on page 15–2)
48. REMOVE FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30–6)
SST 09930–00010

A76716
AA
BBBBB
B
A76714
– ENGINE MECHANICALPARTIAL ENGINE ASSY (1ZZ–FE/3ZZ–FE)(From
February, 2004)14–25
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
(f) Install the front suspension member brace LH and RH
with the 8 bolts.
Torque:
133 N⋅m (1,356 kgf⋅cm, 98 ft⋅lbf) for bolt A
80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) for bolt B
121. INSTALL FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH
(See Pub. No. RM1018E on page 30–6)
122. INSTALL FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
123. INSTALL FRONT STABILIZER LINK ASSY LH (See Pub. No. RM1018E on page 30–6)
124. INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
125. INSTALL TIE ROD END SUB–ASSY LH (See Pub. No. RM1018E on page 30–6)
126. INSTALL TIE ROD END SUB–ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
127. INSTALL FRONT AXLE HUB LH NUT (See Pub. No. RM1018E on page 30–6)
128. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
129. INSTALL EXHAUST PIPE ASSY FRONT (See Pub. No. RM1018E on page 15–2)
130. INSTALL FLOOR PANEL BRACE FRONT
Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf)
131. INSTALL STEERING INTERMEDIATE SHAFT (See Pub. No. RM1018E on page 50–9)
132. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19–7)
133. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
HINT:
1ZZ–FE (See Pub. No. RM1018E on page 55–74)
3ZZ–FE (See Pub. No. RM1018E on page 55–70)
134. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)

(See Pub. No. RM1018E on page 41–15)
135. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
(See Pub. No. RM1018E on page 40–11)
136. INSTALL BATTERY CARRIER
(a) Install the battery carrier and bracket with the 4 bolts.
Torque: 13 N⋅m (131 kgf⋅cm, 9 ft⋅lbf)