TOYOTA AVENSIS 2005 Service Repair Manual

I35325
(1)
(3)
(2)
I35324
± HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (3ZZ±FE)
55±71
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.

Since compressor oil remains in the pipes of the vehicle, if a new w/pulley compressor assy
is installed without removing some oil inside, the oil amount becomes excessive, preventing
heat exchange in the refrigerant cycle and causing refrigerant failure.

If the remaining oil in the removed w/pulley compressor assy is too small 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 3 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 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)
12. 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.

I35323
55±72
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (3ZZ±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)
13. 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.)
14.WARM UP ENGINE (See page 55±38)
15.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)

550YX±01
I35991
PulleyWeight Hub
Weight Hub
± HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (3ZZ±FE)
55±69
AVENSIS REPAIR MANUAL (RM1018E)
W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
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

550YR±01
I36810Clamp
I36811Clamp
I35314
I35315
±
HEATER & AIR CONDITIONER BLOWER ASSY
55±65
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±64
1.REMOVE INSTRUMENT PANEL LOWER ASSY (See page 71±11)
HINT:
Refer to the instructions for removal of the instrument panel lower assy\
.
2.REMOVE ECM (See page 10±65)
3.REMOVE AIR DUCT NO.2 (See page 55±55)
4. REMOVE BLOWER ASSY
(a) Disconnect the connector and the clamp.
(b) RHD Auto A/C:Disconnect the connector and the clamp.
(c) Disconnect the connectors.
(d) Remove the 2 nuts.
(e) Remove the 2 bolts and the 2 screws.
(f) Release the claw fitting and remove the blower assy.

I353162 Claws
I35318
I35319Clamp
I35320
55±66
± HEATER & AIR CONDITIONERBLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE AIR FILTER CASE
(a) Release the 2 claw fittings and remove the air filter case.
6. REMOVE AIR FILTER
7. REMOVE RECIRCULATION DAMPER SERVO
SUB±ASSY
(a) Remove the 2 screws and the recirculation damper servo
sub±assy.
8. REMOVE AIR CONDITIONING WIRENO1 (MANUAL
AIR CONDITIONING)
(a) Disconnect the connector.
(b) Release the clump and remove the air conditioning wire
No.1.
9. REMOVE COOLER WIRING NO.1 (AUTO AIR CONDITIONING)
HINT:
Disconnection of the cooler wiring No.1 is the same as the air conditioning wire No.1.
10. REMOVE BLOWER RESISTOR (MANUAL AIR
CONDITIONING)
(a) Remove the 2 screws and the blower resistor.

I35321
I35322
I35317
I36813
I35314
± HEATER & AIR CONDITIONERBLOWER ASSY
55±67
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE BLOWER MOTOR CONTROL (AUTO AIR
CONDITIONING)
(a) Remove the 2 screws and the blower motor control.
12. REMOVE BLOWER W/FAN MOTOR SUB±ASSY
(a) Remove the 3 screws and the blower w/ fun motor sub±
assy.
13. INSTALL AIR FILTER
(a) Install the air filter as shown in the illustration.
14. INSTALL BLOWER ASSY
(a) Install the blower assy with the claw fitting.
(b) Install the blower assy with the 2 bolts and the 2 screws.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf) (Bolt)
(c) Install the 2 nuts.
(d) Connect the connectors.

I36811Clamp
I36810Clamp 55±68
± HEATER & AIR CONDITIONERBLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(e) RHD Auto A/C:
Connect the connector and the clamp.
(f) Connect the connector and the clamp.

550YQ±01
I35277
Blower Assy
Air Duct No.2
Recirculation Damper Servo Sub±assy
Air Filter
Air Filter Case
Blower w/ fan Motor Sub±assy
Manual A/C:
Blower Resistor Air Conditioning Wire No.1
Auto A/C:
Blower Motor Control
9.8 (100, 87 in.
lbf)
Cooler Wiring No.1Manual A/C:
N
m (kgf
cm, ft
lbf): Specified torque
55±64
± HEATER & AIR CONDITIONERBLOWER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
BLOWER ASSY
COMPONENTS

550YW±01
I03839
PushSST Pull
Release
Lever
I06919
Screw
Driver
Disconnect the
tube using hand
I35293
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
55±55
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±53
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 SUCTION
HOSE NO.1
(a) Install SST on the piping clamp. SST 09870±00025
HINT:
Make sure the direction of the piping clamp claw and SST by
checking the illustration shown on the caution label.
(b) Push down SST and release the clamp lock.
NOTICE:
Be careful not to deform the tube when pushing SST.
(c) Pull SST slightly and push the release lever, and then re- move the piping clamp with SST.
(d) Disconnect the cooler refrigerant suction hose No.1.
NOTICE:

Do not use a screwdriver or similar tool to disconnect
the tube.

Seal the opening of the disconnected parts using vi-
nyl tape to prevent moisture and foreign matter from
entering.
3. DISCONNECT LIQUID TUBE SUB±ASSY A SST 09870±00015
HINT:
Disconnection of the liquid tube sub±assy A is the same as the cooler\
refrigerant suction hose No.1.
4. DISCONNECT HEATER INLET WATER HOSE
(a) Using pliers, grip the claws of the clip and slide the clip todisconnect the heater inlet water hose.

I352944 Claws
Clamp
I352955 Claws
I352966 Claws
I35297
6 Claws
55±56
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5.DISCONNECT HEATER OUTLET WATER HOSE
HINT:
Disconnection of the heater outlet water hose is the same way as the hea\
ter inlet water hose.
6.REMOVE INSTRUMENT PANEL LOWER ASSY (See page 71±11)
HINT:
Refer to the instructions for removal of the instrument panel lower assy\
.
7.REMOVE ECM (See page 10±65) 8. REMOVE HEATER TO REGISTER DUCT NO.1
(a) Remove the 2 clips and screw.
(b) Release the 4 claw fittings and the clip and remove theheater to register duct No.1.
9. REMOVE DEFROSTER NOZZLE ASSY
(a) Release the 5 claw fittings and remove the defroster nozzle assy.
10. REMOVE AIR DUCT REAR NO.3
(a) Release the 6 claw fittings and remove the air duct rear No.3.
11. REMOVE AIR DUCT REAR NO.4
(a) Release the 6 claw fittings and remove the air duct rear No.4.