cooling TOYOTA AVENSIS 2005 Service Manual PDF

±
COOLING WATER PUMP ASSY(1CD±FTV)
16±49
AVENSIS REPAIR MANUAL (RM1018E)
41.SET NO. 1 CYLINDER TO TDC/COMPRESSION
SST09960±10010 (09962±01000, 09963±01000)
42.INSTALL TIMING BELT(See page 14±307)
43.CHECK VALVE TIMING(See page 14±307)
44.INSTALL TIMING CHAIN COVER PLATE(See page 14±307)
45.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET(See page 14±307)
46.INSTALL TIMING BELT GUIDE(See page 14±307)
47.INSTALL TIMING BELT NO.1 COVER(See page 14±307)
48.INSTALL TIMING BELT NO.2 COVER(See page 14±307)
49.INSTALL IDLER PULLEY SUB±ASSY(See page 11±69)
50.INSTALL CRANKSHAFT PULLEY(See page 14±307) SST 09213±54015 (90105±08076), 09330±00021
51.INSTALL ENGINE MOUNTING INSULATOR SUB±ASSY RH(See page 14±307)
52.INSTALL POWER STEERING IDLE PULLEY BRACKET (See page 14±286)
53.ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14±269)
54.INSTALL INJECTOR DRIVER(See page 11±69)
55. INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
56. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
57.ADD ENGINE COOLANT(See page 16±44)
58.CHECK FOR ENGINE COOLANT LEAKS(See page 16±44)
59.CHECK FOR FUEL LEAKS(See page 11±60)

5507E±03
AC2810
AC2811
N11084
Wrong Okay
HI
LO HI LO
± HEATER & AIR CONDITIONERAIR 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.

550Z7±01
I35292
Sight Glass
55±24
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
REFRIGERANT
ON±VEHICLE INSPECTION
1. RHD AZ Engine series:
INSPECT REFRIGERANT VOLUME
(a) Observe the sight glass on the cooler refrigerant liquid
pipe A.
Test conditions:

All doors are fully open.

Temperature control dial is at ºMAX. COOLº.

Engine is running at 1,500 rpm.

Blower speed control switch is at ºHIº.

A/C switch is ON.
ItemSymptomAmount of refrigerantCorrective Actions
1Bubbles existInsufficient*
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
2No bubbles existEmpty, insufficient or excessiveRefer to 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
4Considerable temperature difference be-
tween compressor inlet and outletProper or excessiveRefer to 5 and 6
5Immediately after air conditioning is turned
off, refrigerant remains clearExcessive
(1) Discharge refrigerant
(2) Vacuum and supply proper amount of
new refrigerant
6
Immediately after air conditioning is turned
off, refrigerant foams and then becomes
clear
Proper±
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

I22118
Condition: Air conditioning system does not function effectively.
I22119
Condition: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±27
AVENSIS REPAIR MANUAL (RM1018E)
(3) When cooling is insufficient:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is low on both low and
high pressure sides

RHD AZ engine series:
Bubbles are seen through sight
glass continuously

Cooling performance is insuffi-
cient
Gas leakage in refrigeration sys-
tem
Insufficient refrigerant

Refrigerant leakage
(1) Check for gas leakage and re-
pair if necessary
(2) Supply proper amount of new
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leak-
age.
(4) When the circulation of the refrigerant is poor:
SymptomProbable causeDiagnosisCorrective Action

Pressure is low on both low and
high pressure sides

Frost exists on piping from con-
denser to A/C unit
Refrigerant flow is obstructed by
dirt in condenserCondenser is cloggedReplace condenser

I22120
Condition: Air conditioning system does not function. (Sometimes it may function)
I22121
Condition : Air conditioning system does not function effectively. 55±28
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(5) When the refrigerant does not circulate:
SymptomProbable causeDiagnosisCorrective Actions

Vacuum is indicated on low pres-
sure side, and extreamly low pres-
sure is indicated on high pressure
side

Frost or dew is seen on piping on
both sides of condenser or expan-
sion valve

Refrigerant flow is obstructed by
moisture or dirt in refrigeration sys-
tem

Refrigerant flow is obstructed by
gas leak from expansion valve
Refrigerant does not circulate
(1) Check the expansion valve
(2) Clean out dirt on expansion
valve by blowing air
(3) Replace condenser
(4) Vacuum and supply proper
amount of new refrigerant
(5) For gas leakage from expan-
sion valve, replace expansion
valve
(6) When the refrigerant is overcharged or cooling of
condenser is insufficient:
SymptomProbable causeDiagnosisRemedy

Pressure is extreamly high on
both low and high pressure sides

RHD AZ engine series:
No air bubbles are seen through
sight glass even when engine rpm
lowers

Excessive refrigerant

Cooling performance of con-
denser is insufficient
Excessive refrigerant

Cooling performance of con-
denser is insufficient
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check the amount of refrig-
erant and supply proper amount of
refrigerant

I22118
Condition: Air conditioning system does not function effectively.
I22119
Condition : Air conditioning system does not function effectively. 55±34
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(3) When cooling is insufficient:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is low on both low and
high pressure sides

Cooling performance is insuffi-
cient
Gas leakage in refrigeration sys-
tem
Insufficient refrigerant

Refrigerant leakage
(1) Check for gas leakage and re-
pair if necessary
(2) Supply proper amount of new
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leak-
age.
(4) When the circulation of the refrigerant is poor:
SymptomProbable causeDiagnosisCorrective Action

Pressure is low on both low and
high pressure sides

Frost exists on piping from con-
denser to unit
Refrigerant flow is obstructed by
dirt in condenserCondenser is cloggedReplace condenser

I22120
Condition: Air conditioning system does not function. (Sometimes it may function)
I22121
Condition : Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±35
AVENSIS REPAIR MANUAL (RM1018E)
(5) When the refrigerant does not circulate:
SymptomProbable causeDiagnosisCorrective Actions

Vacuum is indicated on low pres-
sure side, and extreamly low pres-
sure is indicated on high pressure
side

Frost or dew is seen on piping on
both sides of condenser or refrig-
erant filter

Refrigerant flow is obstructed by
moisture or dirt in refrigeration sys-
tem

Refrigerant filter is clogged
Refrigerant does not circulate
(1) Check the refrigerant filter
(2) Clean out dirt on refrigerant fil-
ter by blowing air
(3) Replace condenser
(4) Vacuum air and supply proper
amount of new refrigerant
(5) If refrigerant filter is damaged,
replace it
(6) When the refrigerant is overcharged or cooling of
condenser is insufficient:
SymptomProbable causeDiagnosisRemedy

Pressure is extreamly high on
both low and high pressure sides
Excessive refrigerant

Cooling performance of con-
denser is insufficient
Excessive refrigerant

Cooling performance of con-
denser is insufficient

Magnet valve assy is defective
(1) Clean condenser fins
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, vacuum and supply proper
amount of refrigerant
(4) If pressure is still high even af-
ter supplying refrigerant, replace
the magnet valve assy

760WY±01
B67425
Claw
B67431
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±3
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1. REMOVE FRONT BUMPER COVER
(a) Put protective tape under the front fender.
HINT:
Because the spoiler covers LH and RH are assembled, remove
them together.
(b) Remove the spoiler.
(1) Remove the 9 screws and 6 claws.
(2) Remove the 6 retainers.
(3) Remove the spoiler covers LH and RH together.
(4) Remove the bolt and separate the spoiler cover RH
from the LH.
(c) Remove the 3 bolts and 2 clips.
(d) Using a screwdriver, disengage the 6 claws and remove
the bumper cover.
HINT:
Tape the screwdriver tip before use.
(e) w/ Fog lamp:
Disconnect the fog lamp connectors.
2. R E M O V E H E A D L A M P WA S H E R A C T U ATO R
SUB±ASSY LH (W/ HEADLAMP CLEANER)
(a) Remove the washer hose clip.
(b) Using a screwdriver, pry out the front washer nozzle.
HINT:
Tape the screwdriver tip before use.
(c) Remove the 2 screws and actuator.
3. REMOVE HEADLAMP WASHER ACTUATOR SUB±ASSY RH (W/ HEADLAMP CLEANER)
HINT:
Use the same procedures described for the LH side.
4. REMOVE INTERCOOLER COOLING AIR DUCT SUB±ASSY (W/ CAC 1CD±FTV ENGINE TYPE)
(a) Remove the 3 screws and air duct.
5. REMOVE FRONT BUMPER REINFORCEMENT SUB±ASSY
(a) Using a screwdriver, remove the wire harness.
(b) Remove the 8 bolts and reinforcement.
6. REMOVE FRONT BUMPER SIDE RETAINER LH
(a) Using a screwdriver, remove the 2 screws and retainer.
HINT:
Tape the screwdriver tip before use.

760WX±01
B67422
Front Bumper CoverCAC Cooling
Air Duct Sub±assy Front Bumper
Reinforcement Sub±assy
Front Bumper Side
Retainer LH Front Bumper Side
Retainer RH
w/ Fog Lamp
Fog Lamp
Assy RH
Front Bumper Hole
Cover LH Front Bumper Hole
Cover RH
Front Spoiler
Cover LH Front Spoiler
Cover RHFront Bumper Side
Moulding LH Front Bumper Side
Moulding RHHood to Front
End Panel Seal Radiator GrilleRadiator Grille Lower
w/ CAC
Front Bumper
Stay Sub±assy LH Front Bumper
Stay Sub±assy RH
w/ Fog Lamp
Fog Lamp Assy LH
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BUMPER
COMPONENTS

031H4−02
− SERVICE SPECIFICATIONSCOOLING
03−21
AVENSIS Supplement (RM1045E)
TORQUE SPECIFICATION
2AZ−FSE:
Part TightenedN
mkgf
cmft
lbf
Water pump x Cylinder block9.09280 in.
lbf
Water pump x Water pump pulley2626519
Water inlet x Cylinder block9.09280 in.
lbf
Radiator support upper x Body1919414
Fan assy w/ motor x Radiator6.06153 in.
lbf
Radiator relay block x Radiator5.05446 in.
lbf
1CD−FTV:
Part TightenedN
mkgf
cmft
lbf
Drain plug1313310
Water pump x Cylinder block3132023
Injection pipe x Common rail
With SST
Without SST
31
34316
34723
25
Injection pipe x Injector
For used pipe With SST
Without SST
For new pipe With SST
Without SST
36
40
31
34372
408
316
34727
30
23
25
Fuel inlet pipe sub−assy x Common rail assy
With SST
Without SST
31
34316
34723
25
Fuel inlet pipe sub−assy x Injection pump
With SST
Without SST
31
34316
34723
25
Timing belt idler Sub−assy No.1 x Cylinder head3535726
Front wheel1031,05076