heater TOYOTA AVENSIS 2005 Service Repair Manual

A89208
N·m (kgf·cm, ft·lbf)
: Specified torque
zNon−reusable part Water By−pass Hose No. 1 Heater Water
Inlet HoseIntake Air Control ValveInsulatorIntake ManifoldVentilation Hose
zGasket
30 (306, 22)
zGasket
30 (306, 22)
14−18
− ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)

A79158
A79159
A79156
A79157
−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)13 −13
AVENSIS Supplement (RM1045E)
11. SEPARATE HEATER PUMP ASSY (W/ COLD AREA)
(a) Remove the nut, then disconnect the connector.
(b) Separate the heater pump.
12. REMOVE HEATER BRACKET (W/ COLD AREA)
(a) Remove the bolt and heater bracket.
13. REMOVE FLOOR PANEL BRACE FRONT (See page 15 −6)
14. REMOVE EXHAUST PIPE ASSY FRONT (See page 15 −6)
15. REMOVE EXHAUST PIPE ASSY (W/ COLD AREA)
(a) Remove the 2 nuts.
(b) Remove the 2 nuts and exhaust pipe sub −assembly.

A85753
13−18−
INTAKE TURBOCHARGER SUB −ASSY (1CD −FTV)(From
September, 2003)
AVENSIS Supplement (RM1045E)
38. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay No. 2, then temporarily tighten the bolt.
(b) Temporarily tighten the nut while pushing the manifold
stay No. 2 toward the cylinder head.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
HINT:
No clearance between the stay and cylinder head should be
confirmed.
(c) Tighten the bolt.
Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
(d) Tighten the nut. Torque: 56 N
m (571 kgf
cm, 41 ft
lbf)
39. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.2 (See page 14 −108)
SST 09023 −38200
40. INSTALL VACUUM TRANSMITTING PIPE SUB −ASSY NO.1 (See page 14 −108)
SST 09023 −38200
41. INSTALL EXHAUST GAS TEMPERATURE SENSOR (See page 14 −108)
SST 09023 −38400
42. INSTALL EGR PIPE INSULATOR Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
43. INSTALL GENERATOR ASSY (See Pub. No. RM1018E on page 19 −29)
44. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)
45. INSTALL TURBO INSULATOR NO.1 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
46. INSTALL TURBO INSULATOR NO.2 Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
47. INSTALL EXHAUST PIPE ASSY (W/ COLD AREA) Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
48. INSTALL EXHAUST PIPE ASSY FRONT (See page 15 −6)
49. INSTALL FLOOR PANEL BRACE FRONT (See page 15 −6)
50. INSTALL HEATER BRACKET (W/ COLD AREA)
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
51. INSTALL HEATER PUMP ASSY (W/ COLD AREA)
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
52. INSTALL FUEL FILTER ASSY (See Pub. No. RM1018E on page 11 −82)

A88419
Disconnect Wire
from Terminal B
Generator Voltmeter
BatteryAmmeter
− STARTING & CHARGINGCHARGING SYSTEM (2AZ−FSE)
19−7
AVENSIS Supplement (RM1045E)
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine, then check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
7. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a tester is not available, connect a voltmeter to the
charging circuit as follows:
(1) Disconnect the wire from terminal B of the genera-
tor, then connect it to the negative (−) lead of the
ammeter.
(2) Connect the positive (+) lead of the ammeter to ter-
minal B of the generator.
(3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (−) lead of the voltmeter.
(b) Check the charging circuit.
(1) Keep the engine speed at 2,000 rpm, then check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
8. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn the high beam headlights ON and turn the heater blower
switch to the ”HI” position.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
SIf the ammeter reading is less than the standard amperage, repair the generator.
SIf the battery is fully charged, the indication will sometimes be less than the standard amperage.

551AN−01
I35326
I35327
I35328
55 −4
−
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (2AZ −FSE)
AVENSIS Supplement (RM1045E)
REPLACEMENT
1 . DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(See Pub. No. RM 1018E, page 55 −38)
SST 07110 −58060 ( 07117 −58080, 07117 −58090, 07117 −78050, 07117 −88060, 07117 −88070,
07117 −88080)
2. DI SCO NNECT CO O L ER REFRI G ERANT SUCTI O NHOSE NO. 1
(a) Remove the bolt and disconnect the cooler refrigerant
suction hose No.1 from the w/pulley compressor assy.
(b) Remove the O −ring from the cooler refrigerant suction
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
3. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO. 1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/pulley compressor assy.
(b) Remove the O −ring from the cooler refrigerant discharge
hose No.1.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4. REMOVE RADIATOR SUPPORT OPENING COVER (See page 14− 5)
5. REMOVE ENGINE ROOM COVER SIDE (See page 14− 5)
6. REMOVE ENGINE UNDER COVER RH (See page 14− 5)
7. REMOVE FAN AND GENERATOR V BELT (See page 14− 5)
SST 09249 −63010
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.

I35328
(1)(2)
(3)
(4)
−
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (2AZ −FSE)
55 −5
AVENSIS Supplement (RM1045E)
9. INSPECT COMPRESSOR OIL
(a) When replacing the w/pulley compressor assy with a new one, after gradually removing the refrigerant
gas from the service valve, drain the following amount of oil from the new w/pulley compressor assy
before installation.
Standard:
(Oil capacity inside new w/pulley compressor assy: 90 + 15 cc (3.0 + 0.5 fl. oz.) ) − (Remaining
oil amount in the removed w/pulley compressor assy) = (Oil amount to be removed when replac-
ing)
NOTICE:
S When checking the compressor oil level, observe the precautions on the cooler removal/instal-
lation.
S 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.
S If the remaining oil in the removed w/pulley compressor assy is too small in volume, check for
oil leakage.
S 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 4 bolts.
Torque: 29 N
m (300 kgf
cm, 2 1 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 FAN AND GENERATOR V BELT (See page 14− 5)
SST 09249 −63010
12. 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.

I35327
I35326
55−6
− HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (2AZ−FSE)
AVENSIS Supplement (RM1045E)
(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)
13. 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.
(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)
14. CHARGE REFRIGERANT (See Pub. No. RM1018E, page 55−38)
SST 07110−58060 (07117−58060, 07117−58070, 07117−58080, 07117−58090, 07117−78050,
07117−88060, 07117−88070, 07117−88080)
Specified amount: 440á30 g (15.51á1.06 oz.)
15. WARM UP ENGINE (See Pub. No. RM1018E, page 55−38)
16. INSPECT LEAKAGE OF REFRIGERANT (See Pub. No. RM1018E, page 55−38)

D25215
90−100_C(194−230_F)
C50186
Match−marks
C50232
C50233
D25605
SST 40−126
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90−110_C. (194.0−230.0_F)
NOTICE:
Do not overheat the ring gear to110_C (230.0_F) or more.
(b) Clean the contact surface of the front differential case.
(c) Set the match−marks, install the front differential ring gear
case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
(d) Temporarily install the 8 bolts as shown in the illustration.
(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1N
m (970 kgf
cm, 70 ft
lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223−15020, 09950−70010 (09951−07100)
(b) Coat the rip of oil seal with a little MP grease.

D26384
D26450
Differential Assy
D25215
90−100_C(194−230_F)
D26445
Mark
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40−113
U151E, U151F A/T REPAIR MANUAL (RM1021U)Mark ThicknessMark Thickness
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(f) Remove the16 bolts and the transaxle housing.
(g) Remove the differential assy.
16. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90−110_C(194.0−230.0_F).
NOTICE:
Do not overheat the ring gear to110_C (230.0_F) or more.
(b) Clean the contact surface of the front differential case.
(c) Align the match−marks, install the front differential ring
gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.

05JOB–03
– DIAGNOSTICSSFI SYSTEM (1ZZ–FE/3ZZ–FE)(From February, 2004)
05–21
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
FAIL–SAFE CHART
If any of the following DTCs are recorded, the ECM enters fail–safe mode.
DTC No.Fail–Safe OperationFail–Safe Deactivation Condition
P0031
P0032Heated oxygen sensor (Sensor 1) heater is turned offIgnition switch turned to OFF
P0037
P0038Heated oxygen sensor (Sensor 2) heater is turned offIgnition switch turned to OFF
P0100
P0102
P0103Ignition timing is calculated from engine RPM and Throttle
Position (TP)”Pass” condition detected
P0110
P0112
P0113
Intake Air Temperature (IAT) is fixed at 20
C (68
F)”Pass” condition detected
P0115
P0117
P0118
Engine Coolant Temperature (ECT) is fixed at 80
 
”Pass” condition detected
P0120
P0122
P0123
P0220
P0222
P0223
P2102
P2103
P2111
P2112
P2118
P2119
P2135
When Electronic Throttle Control System (ETCS) is mal-
functioning, electric current to throttle actuator is cut off and
throttle valve returns to throttle position (TP) 16 by its
spring.
Then, required engine power is calculated using ignition
timing and Accelerator Pedal Position (APP). Engine is
controlled by intermittent fuel–cut.
As a result, fully slowly depressing accelerator pedal en-
ables driving at minimum speed. However, quickly depress-
ing pedal would vary vehicle speed remarkably.
”Pass” condition detected followed by the ignition switch
turned to OFF
P0121Fuel is cut intermittently”Pass” condition detected followed by the ignition switch
turned to OFF
P0325
P0327
P0328
Maximum ignition timing retardationIgnition switch turned to OFF
P0351
P0352
P0353
P0354
Fuel is cut”Pass” condition detected
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138
Accelerator Pedal Position (APP) sensor has main circuit
and associate circuit. When one of circuits is malfunction-
ing, APP is calculated by output of other circuit. When both
of circuits are malfunctioning, it is interpreted that accelera-
tor pedal is releasing. As a result, throttle valve is closed
and engine idles.
”Pass” condition detected followed by the ignition switch
turned to OFF