2003 TOYOTA AVENSIS oil level

I35328
(1)(2)
(3)
(4)
I35327
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
55±79
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

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

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

If the remaining oil in the removed w/pulley compressor assy is too smal\
l 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 4 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 FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010
12. INSTALL COOLER REFRIGERANT DISCHARGEHOSE 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)
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.
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I35333
I35333
(1)(2)
(3)
(4)
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
55±87
AVENSIS REPAIR MANUAL (RM1018E)
10. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
11. 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 r\
emoved when replac-
ing)
NOTICE:

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

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

If the remaining oil in the removed w/pulley compressor assy is too smal\
l in volume, check for
oil leakage.

Be sure to use ND±OIL 8 for compressor oil.
12. INSTALL W/PULLEY COMPRESSOR ASSY
(a) Install the w/pulley compressor assy with the 4 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.
13. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
14. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 55±46)
15. FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)
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I35325
(1)(2)
(3)
I35324
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1ZZ±FE)
55±75
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

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

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

If the remaining oil in the removed w/pulley compressor assy is too smal\
l 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.
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I35325
(1)(3) (2)
I35324
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
55±71
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

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

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

If the remaining oil in the removed w/pulley compressor assy is too smal\
l 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.
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710CM±02
±
INSTRUMENT PANEL/METERCOMBINATION METER
71±1
AVENSIS REPAIR MANUAL (RM1018E)
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Discharge warning light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
Brake warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
ABS warning light does not come on.
1.Wire Harness or Connector
2.Skid control ECU
3.Combination Meter Assy±
±
±
SRS warning light does not come on.
1.Wire Harness or Connector
2.Airbag Sensor Assy
3.Combination Meter Assy±
05±1197 ±
Open Door warning light does not come on.
1.Wire Harness or Connector
2.Front Door Courtesy Light
3.Body ECU
4.Combination Meter Assy±
±
±
±
Fuel Level warning light does not come on.
1.Wire Harness or Connector
2.Fuel Sender Gauge
3.Combination Meter Assy±
±
±
Low Oil Pressure warning light does not come on.
1.Wire Harness or Connector
2.Low Oil Pressure Warning Switch
3.Combination Meter Assy±
±
±
Engine Oil Level warning light does not come on.
1.Wire Harness or Connector
2.Oil Level Sensor
3.Combination Meter Assy±
±
±
Belt warning light does not come on.
1.Wire Harness or Connector
2.Body ECU
3.Front Inner Belt Assy
4.Combination Meter Assy±
±
05±1522
±
VSC warning light does not come on.
1.Wire Harness or Connector
2.VSC Circuit
3.Combination Meter Assy±
05±752 ±
Indicator Lights:
SymptomSuspect AreaSee page
Shift indicator light do not come on.
1. Wire Harness or Connector
2. ECM
3. Neutral Start Switch Circuit
4. Combination Meter Assy±
±
±
±
Turn indicator light does not come on.
1. Wire Harness or Connector
2. Turn Signal and Hazard Warning System
3. Combination Meter Assy±
65±9 ±
Glow indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy±
±
±
TRC off indicator light does not come on.
1. Wire Harness or Connector
2. VSC Circuit
3. Combination Meter Assy±
05±752 ±
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71±2
±
INSTRUMENT PANEL/METERCOMBINATION METER
AVENSIS REPAIR MANUAL (RM1018E)
SLIP indicator light does not come on.
1.Wire Harness or Connector
2.Skid Control ECU
3.Combination Meter Assy±
05±752 ±
CRUISE indicator light does not come on.
1.Wire Harness or Connector
2.ECM
3.Combination Meter Assy±
±
±
High Beam indicator light does not come on.
1.Wire Harness or Connector
2.Headlight Dimmer Switch
3.Combination Meter Assy±
65±9 ±
Fr FOG indicator does not come on.
1.Wire Harness or Connector
2.Fr FOG Relay
3.Fr FOG Light Switch
4.Combination Meter Assy±
±
±
±
Rr FOG indicator does not come on.
1.Wire Harness or Connector
2.Rr FOG Relay
3.Rr FOG Light Switch
4.Combination Meter Assy±
±
±
±
TAIL indicator does not come on.
1.Wire Harness or Connector
2.TAIL Relay
3.Combination Meter Assy±
±
±
WATER LEVEL indicator does not come on (1KD±FTV).
1.Wire Harness or Connector
2.Water Level Sensor
3.Combination Meter Assy±
±
±
EMPS indicator does not come on.
1.Wire Harness or Connector
2.EMPS ECU
3.Combination Meter Assy±
±
±
A/T OIL TEMP indicator does not come on.
1.Refer to troubleshooting
2.Wire Harness or Connector
3.Combination Meter Assy05±856
±
±
ECT SNOW indicator does not come on.
1.Refer to troubleshooting
2.Wire Harness or Connector
3.Combination Meter Assy05±980±
±
AUTO LEVELING indicator does not come on.
1.Wire Harness or Connector
2.Auto Leveling ECU
3.Combination Meter Assy±
±
±
Meter Gauges:
SymptomSuspect AreaSee page
Speedometer does not operate.1.Refer to troubleshooting05±1510
Water temperature does not operate.1.Refer to troubleshooting05±1515
Tachometer does not operate.1.Refer to troubleshooting05±1513
Fuel Gauge does not operate or operates abnormally.1.Refer to troubleshooting05±1517
OTHERS:
SymptomSuspect AreaSee page
key reminder buzzer does not operate.
1. Wire Harness or Connector
2. Body ECU (KSW, DCTY)
3. Door Coutesy Switch
4. Key Unlock Warning Switch
5. Combination Meter Assy±
±
±
05±1586 ±
Light reminder buzzer does not operate.
1. Wire Harness or Connector
2. Body ECU (DCTY)
3. Combination Meter Assy±
±
±
Seat belt Warning buzzer does not operate.
1. Perform DATA LIST with hand±held tester
2. Wire Harness or Connector
3. Seat Belt Buckle Switch
4. Combination Meter Assy05±1499±
61±3
±
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IG
SPEED
BKL SW
(D±seat)
BKL SW
(P seat)
WRN LAMP
BUZZERON
OFF
15km/h
0
BELT ON
BELT OFF
LVL1
LVL2 BELT ON
BELT OFF
ON
OFF OFF
30s
90s30s90s
±
INSTRUMENT PANEL/METER COMBINATION METER
71±5
AVENSIS REPAIR MANUAL (RM1018E)
7. INSPECT SEAT BELT WARNING LIGHT & BUZZER
(a) Check the operation.
(1) Turn the ignition switch to ON and check that the warning light comes on.\
(2) Fasten the outer belt to the inner belt and check that the warning light\
goes out.
(3) Disconnect the connector from the buckle switch and ground the terminal \
on the wire harness
side connector.
(4) Turn the ignition switch to ON and check that the warning light comes on.\
8. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Inspect the circuit. (1) Disconnect the connector from the low oil pressure switch.
(2) Turn the ignition switch to ON.
(3) Ground the terminal of the wire harness side connector, then check the low oil pressure warninglight.
Low oil pressure warning light: Come on
9. INSPECT BRAKE WARNING LIGHT
(a) Inspect the parking brake warning light.
(1) Disconnect the connector from the parking brake switch and ground the terminal on the wire har-ness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
(b) Inspect the brake fluid level warning light.
(1) Disconnect the connector from the brake fluid level warning switch and c\
onnect the terminalson the wire harness side connector.
(2) Turn the ignition switch to ON and check that the warning light comes on.\
10. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Inspect the continuity.
(1) Remove the reservoir tank cap and strainer.
(2) Disconnect the connector.
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38AVENSIS (EWD526E)
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
[LHD : 1AZ–FSE]
A5
F6
C6
A10
H2
H6
F11
F9
(*1)
(*2) *1:w/ HID
*2:w/o HID
F10
F2
E4
A6
A4
E5
F5
B1
H1
H5
E2
F7
F8
H9C2H10F16H7C1H8B3B2F13F12
H12A12A3C3A11H3F4H4H11A1A2E1A9F3F1
C5
(A/T)
(*1)
(*2)
(M/T)
A 1 A/C Ambient Temp. Sensor
A 2 A/C Condenser Fan Motor
A 3 A/C Pressure Sensor
A 4 ABS Speed Sensor Front LH
A 5 ABS Speed Sensor Front RH
A 6 Air Flow Meter
A 9 Airbag Sensor Front LH
A 10 Airbag Sensor Front RH
A 11 Alternator
A 12 Alternator
B 1 Back–Up Light SW
B 2 Brake Booster Pressure Sensor
B 3 Brake Fluid Level Warning SW
C 1 Camshaft Position Sensor
C 2 Camshaft Timing Oil Control Valve
C 3 Compressor Assembly
C 5 Counter Gear Speed Sensor
C 6 Crankshaft Position Sensor
E 1 ECT Solenoid
E 2 EFI Water Temp. Sensor
E 4 Electronic Driver Unit
E 5 Electronic Driver Unit
F 1 Front Clearance Light LH
F 2 Front Clearance Light RH
F 3 Front Fog Light LH F 4 Front Fog Light RH
F 5 Front Side Turn Signal Light LH
F 6 Front Side Turn Signal Light RH
F 7 Front Turn Signal Light LH
Headlight Control ECU LH
F 8 Front Turn Signal Light LH Headlight LH (Low)
F 9 Front Turn Signal Light RH Headlight Control ECU RH
F 10 Front Turn Signal Light RH Headlight RH (Low)
F 11 Front Washer Motor
F 12 Front Window Deicer
F 13 Front Wiper Motor
F 16 Fuel Pressure Sensor
H 1 Headlight Beam Level Control Actuator LH
H 2 Headlight Beam Level Control Actuator RH
H 3 Headlight Cleaner Control Relay
H 4 Headlight Cleaner Motor
H 5 Headlight LH (High)
H 6 Headlight RH (High)
H 7 Heated Oxygen Sensor (Bank 1 Sensor 1)
H 8 Heated Oxygen Sensor (Bank 1 Sensor 2)
H 9 Heated Oxygen Sensor (Bank 2 Sensor 1)
H 10 Heated Oxygen Sensor (Bank 2 Sensor 2)
H 11 Horn LH
H 12 Horn RH
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