2005 TOYOTA AVENSIS service

I35332
I35330
I35331
55±88
± HEATER & AIR CONDITIONERW/PULLEY COMPRESSOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
16. 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)
17. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1 (RHD STEERING POSITION TYPE)
(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)
18. INSTALL SUCTION SERVIC VALVE (LHD STEERING
POSITION TYPE)
(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 suction service valve.
(d) Install the suction servic valve on the w/pulley compres-
sor assy with the 2 bolts.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
19. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1 (LHD STEERING POSITION TYPE)
(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.

550Z4±01
I35326
I35327
I35328
55±82
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38) SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. DISCONNECT COOLER REFRIGERANT SUCTIONHOSE 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±105)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±105)
6.REMOVE ENGINE UNDER COVER RH (See page 14±105)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±105) SST 09249±63010 8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
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 r\
emoved when replac-
ing)

550Z2±01
I35326
I35327
I35328
55±78
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38) SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. DISCONNECT COOLER REFRIGERANT SUCTIONHOSE 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±185)
5.REMOVE ENGINE ROOM COVER SIDE (See page 14±185)
6.REMOVE ENGINE UNDER COVER RH (See page 14±185)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±185) SST 09249±63010 8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
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 r\
emoved when replac-
ing)

550Z0±01
I35323
I35324
I35325
55±74
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38) SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. DISCONNECT COOLER REFRIGERANT SUCTIONHOSE 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 SUB±ASSY NO.1 (See page 14±5)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 3 bolts and the w/pulley compressor assy.
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 r\
emoved when replac-
ing)

550YY±01
I35323
I35324
I35325
55±70
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38) SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. DISCONNECT COOLER REFRIGERANT SUCTIONHOSE 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 SUB±ASSY NO.1 (See page 14±5)
7.REMOVE FAN AND GENERATOR V BELT (See page 14±5)
8. REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 3 bolts and the w/pulley compressor assy.
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 r\
emoved when replac-
ing)

600JW±01
H40004
SST(s)
H40004
SST(s)
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±19
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
When scrapping a vehicle equipped with the SRS or disposing of a horn button assy, be sure to deploy the
airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag de-
ployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of the horn button assy that has an un-
deployed airbag.

The airbag produces an extremely exploding sound
when it is deployed, so perform the operation out-
doors and where it will not create a nuisance to
nearby residents.

When deploying the airbag, always use the specified
SST(s) (SRS Airbag Deployment Tool). Perform the
operation in a place away from electrical noise.

When deploying the airbag, perform the operation at
least 10 m (33 ft) away from the horn button assy.

The horn button assy is extremely hot when the air-
bag is deployed, so do not touch it for at least 30 min-
utes after deployment.

Use gloves and safety glasses when handling the
horn button assy with the deployed airbag.

Do not apply water, etc. to the horn button assy with
the deployed airbag.

Always wash your hands with water after completing
the operation.
1. DISPOSE OF HORN BUTTON ASSY (WHEN
SCRAPPING VEHICLE DEPLOYMENT METHOD)
HINT:
Prepare a battery as the power source to deploy the airbag.
(a) Check the function of the SST(s).
CAUTION:
When deploying the airbag, always use the specified
SST(s): SRS Airbag Deployment Tool.
SST 09082±00700

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42627
L
M
H42628
SST(s) 60±22
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
CAUTION:

When removing the horn button assy, work must be
started 90 seconds after the ignition switch is turned
to the ºLOCKº position and the negative (±) terminal
cable is disconnected from the battery.

When storing the horn button assy, keep the upper
surface of the airbag deployment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie
down the horn button assy to the disc wheel.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in2. or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the horn button assy, it may be snapped
by the shock when the airbag is deployed. This is highly
dangerous. Always use a wire harness for vehicle use
which has a diameter of at least 1.25 mm
2
(0.0019 in2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 x (Diameter)
2
divided by 4
(1) Install the 2 bolts with washers in the 2 bolts holes
of the horn button assy.
Bolt:
L: 35.0 mm (1.378 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:

Tighten the bolts by hand until the bolts become diffi-
cult to turn.

Do not tighten the bolts too much.
(2) After connecting the SST(s) below to each other,
connect them to the horn button assy.
SST 09082±00802 (09082±10801, 09082±30801)

600JU±01
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±1
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
PRECAUTION
CAUTION:

AVENSIS is equipped with SRS, which comprises of a driver airbag, front passeng\
er airbag,
side airbag, curtain shield airbag and driver knee airbag. Failure to carry \
out service operations
in the correct sequence could cause the SRS to unexpectedly deploy during \
servicing, possibly
leading to serious accident. Further, if a mistake is made in servicing the SRS, it is possible that
the SRS may fail to operate when required. Before performing servicing (in\
cluding removal or
installation of parts, inspection or replacement), be sure to read the \
following items carefully,
then follow the correct procedures indicated in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the º\
LOCKº position and
the negative (±) terminal cable is disconnected from the battery.
(The SRS is equipped with a back±up power source so that if work is started wi\
thin 90 seconds
after disconnecting the negative (±) terminal cable of the battery, the SRS may be deployed.)

Do not expose the horn button assy, instrument panel passenger airbag assy, instrument panel
airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag
sensor assy, curtain shield airbag assy, airbag sensor rear or seat position airbag sensor di-
rectly to hot air or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so DTCs are th\
e most important in-
formation source of information when troubleshooting. When troubleshooting the SRS, always
inspect DTCs before disconnecting the battery.

Even in the case of a minor collision when the SRS does not deploy, the horn button assy, instru-
ment panel passenger airbag assy, instrument panel airbag assy, airbag sensor assy center,
airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy,
airbag sensor rear and seat position sensor must be inspected (See page 60±11).

Before repairs work, remove the airbag sensor if any kind of shock is likely to occur to the sen-
sor during operation.

Never use SRS parts from another vehicle. When replacing the parts, repl\
ace them with new
ones.

Never disassemble nor repair the horn button assy, instrument panel passenger airbag assy,
instrument panel airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag
assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear or seat position
airbag sensor in order to reuse it.

If the horn button assy, instrument panel passenger airbag assy, instrument panel airbag assy,
airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy,
curtain shield airbag assy, airbag sensor rear or seat position airbag sensor has been dropped,
or if there are any cracks, dents or other defects in the case, bracket \
or connector, replace it
with a new one.

Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting the electrical
circuits circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions the notice.

After work on the SRS is completed, perform the SRS warning light check \
(See page 05±1184).