2005 TOYOTA AVENSIS radiator

4105X±04
D30480

D30691
D30482
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±15
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH
9. DRAIN TRANSAXLE OIL
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE CYLINDER HEAD COVER NO.2
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
19. DISCONNECT WIRE HARNESS
(a) Remove the 3 bolts, disconnect the wire harness clamps.
(b) Remove the bolt, disconnect the ground cable.

D30480
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±21
AVENSIS REPAIR MANUAL (RM1018E)
51. INSTALL BATTERY CARRIER
(a) Install the battery carrier and 4 bolts.
Torque: 13 N
m (131 kgf
cm, 9 ft
lbf)
52. INSTALL BATTERY TRAY
53. INSTALL BATTERY
54. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Nut: 3.5 N
m (36 kgf
cm, 31 in.
lbf)
55. INSTALL AIR CLEANER ASSY Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
56. INSTALL CYLINDER HEAD COVER NO.2 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
57. INSTALL ENGINE ROOM COVER SIDE
58. INSTALL RADIATOR SUPPORT OPENING COVER
59. INSTALL HOOD SUB±ASSY Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
60.INSPECT HOOD SUB±ASSY (See page 75±2)
61.ADJUST HOOD SUB±ASSY (See page 75±2)
62.ADD TRANSAXLE OIL (See page 41±3)
63.INSPECT TRANSAXLE OIL (See page 41±2)
64. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
65.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
66.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
67.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
68.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
69. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
70. STEERING WHEEL CENTER POINT
71.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
72. INSTALL ENGINE UNDER COVER LH
73. INSTALL ENGINE UNDER COVER RH
74. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)
75.HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 65±19)

410DS±01
D30478
Battery Clamp Sub±assy
Battery Tray
Charcoal Canister Assy Battery Carrier
Transmission Control Cable AssyClipAir Cleaner Assy
Hood Sub±assy
Cylinder Head Cover No.2
Starter AssyBack±up Lamp
SwitchConnector
Transverse Engine
Engine Mounting Bracket
Clip
Clip
ClipClip
37 (380, 27)
Starter Connector
Transverse Engine
Engine Mounting Insulator
52 (530, 38)
52 (530, 38)
Ground Cable
Gasket
7.0 (71, 62 in.
lbf)
Filler Plug
37 (380, 27)
23 (230, 17)
47 (479, 35)
N´m (kgf´cm, ft´lbf) : Specified torque
19 (195, 14)
13 (130, 9)
64 (653, 47)
64 (653, 47)
5.0 (51, 44 in.
lbf)

Non±reusable part
5.0 (51, 44 in.
lbf)
14 (141, 10)
13 (133, 10)
13 (131, 9)
5.0 (51, 44 in.
lbf)
26 (260, 19)
25 (255, 18)
80 (816, 59)
26 (260, 19)
23 (230, 17)
Engine Room Cover Side
Radiator Support Opening Cover
40 (410, 30)
39 (400, 29)
Manual Transaxle Assy
64 (653, 47)
Battery
Clutch Release Cylinder Assy
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
41±13
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE ASSY (1ZZ±FE/3ZZ±FE)
COMPONENTS

550YV±01
I35275
N
m (kgf
cm, ft
lbf) : Specified torque
9.8 (100, 87 in.
lbf)
9.8 (100, 87 in.
lbf)
Defroster Nozzle Assy
Heater To Register Duct No.1
Blower Assy
Air Conditioning Radiator Assy
Instrument Panel Brace Sub±assy No.1
Air Duct Rear No.3Air Duct Rear No.4
9.8 (100, 87 in.
lbf)
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±53
AVENSIS REPAIR MANUAL (RM1018E)
AIR CONDITIONING RADIATOR ASSY
COMPONENTS

I35276
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part

Compressor oil ND±OIL 8 or equivalentCooler Thermistor No.1
Auto A/C:
Airmix No.2 Damper
Servo Sub±assy
Heater Piping CoverMode Damper Servo
Sub±assy
Airmix Damper Servo Sub±assy
w/o Hot gas heater:
Cooler Expansion Valve
Cooler Evaporator
Sub±assy No.1
Cooler Unit Drain Hose No.1
Air Conditioning
Tube Assy
Heater Radiator Unit Sub±assyAir Duct No.1Air Duct No.2
w/o Hot gas heater:
Air Conditioning
Tube Assy
w/ Hot gas heater:
O±ring


O±ring


3.5 (35, 30 in.
lbf)
Cooler Air Hose
RHD Auto A/C:
Air Conditioning
Wire No.1
55±54
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)

550YP±01
I31981
Bolt B
Nut A
I31981
I31981
Bolt B
Nut A
Measuring
Position
F11928
CORRECT WRONG WRONG 55±46
± HEATER & AIR CONDITIONERV (COOLER COMPRESSOR TO CRANKSHAFT
PULLEY) BELT NO.1
AVENSIS REPAIR MANUAL (RM1018E)
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY)
BELT NO.1
REPLACEMENT
1. REMOVE RADIATOR SUPPORT OPENING COVER
2. REMOVE ENGINE ROOM COVER SIDE
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Loosen the nut A.
(b) Loosen the bolt B and remove the V (cooler compressor
to crankshaft pulley) belt No. 1.
5. INSTALL V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Temporarily install a new V (cooler compressor to crank-
shaft pulley) belt No. 1 as shown in the illustration.
6. ADJUST V (COOLER COMPRESSOR TO
CRANKSHAFT PULLEY) BELT NO.1
(a) Tighten the nut A.
Torque: 2.5 N
m (25 kgf
cm, 22 ft
lbf)
(b) Apply drive belt tension by turning bolt B.
Belt deflection:
New belt: 11 ± 13 mm (0.43 ± 0.51 in.)
Used belt: 13.5 ± 16.5 mm (0.53 ± 0.64 in.)
HINT:

The new belt refers to a belt which is used for less than
5 minutes on the running engine.

The used belt refers to a belt which is used for 5 minutes,
or more on the running engine.

After installing the drive belt, check that the belt fits prop-
erly in the ribbed grooves.

Check that the drive belt does not slip off the groove at the
end of the pulley by hand.

550ZF±01
I32391
55±14
± HEATER & AIR CONDITIONERELECTRICAL TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT HEATER ASSY
(a) Check continuity.
(1) Using an ohmmeter, check for continuity between
each terminal of connector and earth wire.
If no continuity, replace the heater radiator.

550RQ±02
55±6
±
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Whole functions of the A/C system does not operate.
4. ECU±B fuse
5. A/C amplifier assy
6. Wire harness or connector±
55±3 ±
Air Flow Control : No blower operation
1. Blower resistor
2. Heater relay
3. Blower w/ fan motor sub±assy
4. A/C amplifier assy
5. Wire harness or connector55±7
55±7
55±7
55±3±
Air Flow Control : No blower control
1. Blower w/fan motor sub±assy
2. Blower resistor
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3
±
Air Flow Control : Insufficient air out
1. Blower w/fan motor sub±assy
2. Blower resistor
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3±
Temperature Control : No cool air comes out
1. Volume of refrigerant
2. Drive belt tension
3. Refrigerant pressure
4. Cooler compressor assy
5. Pressure sensor
6. Condenser fan
7. Air mix damper servo sub±assy
8. A/C amplifier assy
9. Wire harness or connector55±24
55±46
55±2455±7
55±3 ±
55±7
55±3 ±
Temperature Control : No warm air comes out
1. Engine coolant volume
2. Cooler thermistor No.1
3. Air mix damper servo sub±assy
4. A/C amplifier assy
5. Heater radiator unit sub±assy
6. Wire harness or connector55±7
55±3
55±7
55±3±
±
Temperature Control : Output air is warmer or cooler than the set
temperature or response is slow.1. A/C amplifier assy
2. Air mix damper servo sub±assy
3. Air mix level55±3
55±7
±
Temperature Control : No temperature control
1. A/C amplifier assy
2. Air mix damper servo sub±assy
3. Air mix level55±3
55±7±
No air inlet control
1. Recirculation damper servo sub±assy
2. A/C amplifier assy
3. Wire harness or connector55±7
55±3±
No air outlet control
1. A/C amplifier assy
2. Mode damper servo sub±assy
3. Mode lever55±3
55±7±
Engine idle up does not occur, or is continuous
1. Idle up switch
2. Cooler compressor assy
3. A/C amplifier assy
4. Wire harness or connector55±7
55±7
55±3±
Brightness does not changes when rheostat volume or light con-
trol switch it turned.1. Illumination light system
2. A/C amplifier assy
3. Wire harness or connector±
55±3 ±