2005 TOYOTA AVENSIS checking oil

F05383
Air
Hose Side Vacuum Pump Side
Air
F08981
F08982
New O±Ring
F08970
± BRAKEVACUUM PUMP ASSY (1CD±FTV)
32±37
AVENSIS REPAIR MANUAL (RM1018E)
10. INSPECT CHECK VALVE SUB±ASSY
(a) Check that air flows from the hose side to the pump side.
(b) Check that air does not flow from the pump side to the
hose side.
NOTICE:
Block off the 4 holes on the side surface of the check valve
when checking.
If necessary, replace the check valve.
11. INSTALL VACUUM PUMP COUPLING
(a) Place the vacuum pump coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
12. INSTALL VACUUM PUMP ROTOR SUB±ASSY
(a) Coat the rotor with engine oil, and install it to the rotor shaft.
13. INSTALL VACUUM PUMP BLADE A
(a) Apply the engine oil to the rotor, and install the rotor in the
housing.
(b) Apply the engine oil to the 5 new blades.
(c) Install the 5 blades with the round end facing outward.
NOTICE:
Install so that the blade attaches on the housing.
(d) Coat 2 new O±rings with engine oil, and install them on
the housing.
(e) Using soft jaws on the vise, place the vacuum pump on
the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(f) Place the end cover, and temporarily install the 3 bolts.
(g) Using a pin punch and hammer, drive in the 2 straight
pins.
NOTICE:
Install so that the blade and end cover of the eccentric ring
does not interfere with each other.

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)

I35328
(1)(2)
(3)
(4)
I35327
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
55±83
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±105) 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.

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.

I35325
(1)
(2) (3)
I35324
± HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (1ZZ±FE)
55±75
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.

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.

C68311
C80547
SST
C68244
C68246
D30552
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±55
C250 M/T REPAIR MANUAL (RM1020E)
29. INSTALL SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 1st gear.
30. INSTALL TRANSMISSION CLUTCH HUB NO.1
(a) Using SST and a press, install the transmission clutch
hub No.1 to the output shaft
SST 09316±60011 (09316±00031)
HINT:

The 1st gear can be turned.

While checking the 1st gear thrust washer pin or ball is in-
serted into the groove of the 1st gear thrust washer, press
and fit the clutch hub No.1.
(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.039 in.) or less
MarkThickness mm (in.)MarkThickness mm (in.)
A2.50 (0.0984)D2.68 (0.1055)
B2.56 (0.1008)E2.74 (0.1079)
C2.62 (0.1031)F2.80 (0.1102)
(c) Using brass bar and hammer, install the snap ring to the
output shaft.
31. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing and 2nd gear
bearing spacer with gear oil, install them to the output
shaft.
32. INSTALL SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 2nd gear.

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.