TOYOTA AVENSIS 2005 Service Repair Manual

I352984 Clamps
I35299
I36809
I35300
I36810Clamp
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±57
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE INSTRUMENT PANEL BRACE SUB±ASSY
NO.1
(a) Disconnect the 4 clamps.
(b) Remove the 2 bolts, the screw, the nut and the instrument
panel brace sub±assy No.1.
13. REMOVE AIR CONDITIONER UNIT ASSY
(a) Disconnect the connectors and the clip.
(b) Remove the 2 nuts.
(c) PTC Heater model:
Remove the bolt.
(d) Remove the 2 bolts, the 2 nuts and the air conditioner unit
assy.
14. REMOVE AIR CONDITIONING RADIATOR ASSY
(a) Disconnect the clamp.

I36811Clamp
I35301
I353022 Claws
I353032 Claws
I35304
55±58
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(b) RHD Auto A/C:
Disconnect the clamp.
(c) Remove the 3 screws and air conditioning radiator assy.
15. REMOVE AIR DUCT NO.1
(a) Release the 2 claw fittings and remove the air duct No.1.
16. REMOVE AIR DUCT NO.2
(a) Release the 2 claw fittings and remove the air duct No.2.
17. REMOVE MODE DAMPER SERVO SUB±ASSY
(a) Remove the 3 screws and the mode damper servo sub±
assy.

I35305
I353063 Claws


I35835
LHD:
RHD:4 Claws
I35308
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±59
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE AIRMIX DAMPER SERVO SUB±ASSY
(a) Remove the 2 screws and the airmix damper servo sub±
assy.
19. REMOVE HEATER PIPING COVER
(a) Release the 3 claw fittings and remove the heater piping
cover.
20. REMOVE HEATER RADIATOR UNIT SUB±ASSY
(a) LHD:
Release the 4 claw fittings and remove the clamp.
(b) RHD:
Remove the screw and the clamp.
(c) Remove the heater radiator unit sub±assy.

I35309
I35310Claw
I35311

I37394
55±60
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
21. REMOVE AIR CONDITIONING WIRENO1 (AUTO AIR CONDITIONING)
22. REMOVE AIRMIX NO.2 DAMPER SERVO SUB±ASSY
(AUTO AIR CONDITIONING)
(a) Remove the 2 screws and the airmix No.2 damper servo
sub±assy.
23. REMOVE AIR CONDITIONING TUBE ASSY
(a) Remove the 2 screws.
(b) Release the claw fitting and remove the cover.
(c) Using a hexagon wrench 4.0 mm (0.15 in.), remove the
2 hexagon bolts and the air conditioning tube assy.
(d) w/o Hot gas heater:
Remove the 2 O±rings from the air conditioning tube assy.
24. REMOVE COOLER EXPANSION VALVE (W/O HOT
GAS HEATER)
(a) Remove the cooler expansion valve from the cooler evap-
orator sub±assy No.1.

I35313
I33489
I36814
I33489
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±61
AVENSIS REPAIR MANUAL (RM1018E)
25. REMOVE COOLER THERMISTOR NO.1
(a) Remove the 6 screws and the cover.
(b) Remove the cooler thermistor No.1 and the cooler evapo-
rator sub±assy No.1 from the case.
(c) Remove the cooler thermistor No.1 from the cooler evap-
orator sub±assy No.1.
26. REMOVE COOLER EVAPORATOR SUB±ASSY NO.1
(a) Remove the 2 O±rings from the cooler evaporator sub±
assy No.1.
27. REMOVE COOLER AIR HOSE
(a) Remove the screw and the cooler air hose.
28. REMOVE AIR DUCT ASSY HEATER
29. REMOVE COOLER AIR HOSE (AUTO AIR CONDITIONING)
30. REMOVE COOLER UNIT DRAIN HOSE NO.1
31. INSTALL COOLER EVAPORATOR SUB±ASSY NO.1
(a) Sufficiently apply compressor oil to 2 new O±rings and the
fitting surface of the cooler expansion valve.
Compressor oil: ND±OIL 8 or equivalent
(b) Install the 2 O±rings on the cooler evaporator sub±assy
No.1.

I36812
107 mm
(4.21 in.)
201 mm (7.91 in.)
67 mm
(2.63 in.)
50 mm
(1.96 in.)
I35313

I37394
I35311
I35300
55±62
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
32. INSTALL COOLER THERMISTOR NO.1
(a) Install the cooler thermistor No.1 as shown in the illustra-
tion.
(b) Install the cooler evaporator sub±assy No.1 on the case.
(c) Install the cover with the 6 screws.
33. INSTALL COOLER EXPANSION VALVE (W/O HOT
GAS HEATER)
(a) Install the cooler expansion valve.
34. INSTALL AIR CONDITIONING TUBE ASSY
(a) w/o Hot gas heater:
Sufficiently apply compressor oil to 2 new O±rings and the
fitting surface of the air conditioning tube assy.
Compressor oil: ND±OIL 8 equivalent
(b) w/o Hot gas heater:
Install the 2 O±rings on the air conditioning tube assy.
(c) Using a hexagon wrench 4.0 mm (0.15 in.), install the air
conditioning tube assy with the 2 hexagon bolts.
Torque: 3.5 N
m (35 kgf
cm, 30 in.
lbf)
35. INSTALL AIR CONDITIONER UNIT ASSY
(a) Install the air conditioner unit assy with the 2 bolts and 2
nuts.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)

I35299
I06878
ConnectGapWrong
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
55±63
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the 2 nuts.
(c) Connect the connectors and the clip.
36. 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 cooler refrigerant suction hose No.1.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the 2 O±rings on the cooler refrigerant suction hose No.1.
(d) Install the cooler refrigerant suction hose No.1 and piping clamp.
HINT:
After the connection, check the claw fitting of the piping clamp.
37. INSTALL LIQUID TUBE SUB±ASSY A
(a) Remove the attached vinyl tape from the tube.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting sur\
face of the liquid tube sub±assy A.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the 2 O±rings on the liquid tube sub±assy A.
(d) Install the liquid tube sub±assy A and the piping clamp.
HINT:
After the connection, check the claw fittings of the piping clamp.
38. ADD ENGINE COOLANT 3ZZ±FE/1ZZ±FE: (See page 16±7)
1AZ±FSE: (See page 16±31)
1AZ±FE: (See page 16±19)
1CD±FTV: (See page 16±44)
39. CHECK FOR ENGINE COOLANT LEAKS 3ZZ±FE/1ZZ±FE: (See page 16±1)
1AZ±FSE: (See page 16±25)
1AZ±FE: (See page 16±13)
1CD±FTV: (See page 16±37)
40.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.)
41.WARM UP ENGINE (See page 55±38)
42.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)

600JY±01
H42642
H42643
H42644
Hook
Airbag DoorHook
Front
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±29
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
4. DISCONNECT PASSENGER AIRBAG CONNECTOR
(a) Remove the passenger airbag connector clip.
(b) Disconnect the passenger airbag connector.
5. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
6. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSY
(a) Remove the 2 screws.
(b) Release the rear side wall of the airbag door from the hook by slightly deflecting it and roll the instrument panel
passenger airbag assy forward.
(c) Release the front side wall of the airbag door from the oth-
er hook and remove the instrument panel passenger air-
bag assy.
7. INSTALL INSTRUMENT PANEL PASSENGER AIR BAG ASSY
8.INSPECT INSTRUMENT PANEL PASSENGER AIR BAG ASSY (See page 60±11)
9. INSTALL INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
10.INSPECT SRS WARNING LIGHT (See page 05±1184)

600JX±01
H42775
Instrument Panel Passenger Airbag Assy
Instrument Panel Sub±Assy Upper
Glove Compartment Door Assy
20 (200, 14)
N
m (kgf
cm, ft
lbf): Specified torque 60±28
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL PASSENGER AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL PASSENGER AIR BAG ASSY
COMPONENTS

6009S±04
H42634
H42636 Claw
60±26
±
SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
SPIRAL CABLE SUB±ASSY
REPLACEMENT
HINT:
COMPONENTS: See page 60±16
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.REMOVE HORN BUTTON ASSY (See page 60±17)
5.REMOVE STEERING WHEEL ASSY (See page 50±9) SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±\
05021)
6.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
7.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
8. REMOVE STEERING COLUMN COVER SUB±ASSYLOWER
(a) Remove the 3 screws and the steering column cover sub± assy lower.
9. REMOVE STEERING COLUMN COVER
W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Remove the steering column cover w/instrument cluster finish panel assy.
10. REMOVE SPIRAL CABLE SUB±ASSY
(a) Disconnect the airbag connector and the connector from the spiral cable sub±assy.
(b) Disengage the 3 claws and remove the spiral cable sub±
assy.
11.INSPECT SPIRAL CABLE SUB±ASSY (See page 60±11)
(a) If the following condition is identified, replace the spiral cable sub±\
assy with a new one. Condition:
Scratches or cracks on the connector
Cracks, dents or chips in the spiral cable sub±assy
12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
(a) Check that the front wheels are facing straight ahead.