2005 TOYOTA AVENSIS radiator

550Z6±01
I35329
I35330
I35331
I35332
55±86
±
HEATER & AIR CONDITIONER W/PULLEY COMPRESSOR ASSY (1CD±FTV)
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 (LHD STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the suction servic valve.
(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. REMOVE SUCTION SERVIC VALVE (LHD STEERING
POSITION TYPE)
(a) Remove the 2 bolts and disconnect the suction service valve from the w/pulley compressor assy.
(b) Remove the O±ring from the suction service valve.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
4. DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1 (RHD STEERING POSITION TYPE)
(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.
5. 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.
6. REMOVE RADIATOR SUPPORT OPENING COVER
7. REMOVE ENGINE ROOM COVER SIDE
8. REMOVE ENGINE UNDER COVER RH
9. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55±46)

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)

550YW±01
I03839
PushSST Pull
Release
Lever
I06919
Screw
Driver
Disconnect the
tube using hand
I35293
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
55±55
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±53
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 SUCTION
HOSE NO.1
(a) Install SST on the piping clamp. SST 09870±00025
HINT:
Make sure the direction of the piping clamp claw and SST by
checking the illustration shown on the caution label.
(b) Push down SST and release the clamp lock.
NOTICE:
Be careful not to deform the tube when pushing SST.
(c) Pull SST slightly and push the release lever, and then re- move the piping clamp with SST.
(d) Disconnect the cooler refrigerant suction hose No.1.
NOTICE:

Do not use a screwdriver or similar tool to disconnect
the tube.

Seal the opening of the disconnected parts using vi-
nyl tape to prevent moisture and foreign matter from
entering.
3. DISCONNECT LIQUID TUBE SUB±ASSY A SST 09870±00015
HINT:
Disconnection of the liquid tube sub±assy A is the same as the cooler\
refrigerant suction hose No.1.
4. DISCONNECT HEATER INLET WATER HOSE
(a) Using pliers, grip the claws of the clip and slide the clip todisconnect the heater inlet water hose.

I352944 Claws
Clamp
I352955 Claws
I352966 Claws
I35297
6 Claws
55±56
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5.DISCONNECT HEATER OUTLET WATER HOSE
HINT:
Disconnection of the heater outlet water hose is the same way as the hea\
ter inlet water hose.
6.REMOVE INSTRUMENT PANEL LOWER ASSY (See page 71±11)
HINT:
Refer to the instructions for removal of the instrument panel lower assy\
.
7.REMOVE ECM (See page 10±65) 8. REMOVE HEATER TO REGISTER DUCT NO.1
(a) Remove the 2 clips and screw.
(b) Release the 4 claw fittings and the clip and remove theheater to register duct No.1.
9. REMOVE DEFROSTER NOZZLE ASSY
(a) Release the 5 claw fittings and remove the defroster nozzle assy.
10. REMOVE AIR DUCT REAR NO.3
(a) Release the 6 claw fittings and remove the air duct rear No.3.
11. REMOVE AIR DUCT REAR NO.4
(a) Release the 6 claw fittings and remove the air duct rear No.4.

I352984 Clamps
I35299
I36809
I35300
I36810Clamp
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±57
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE INSTRUMENT PANEL BRACE SUB±ASSY
NO.1
(a) Disconnect the 4 clamps.
(b) Remove the 2 bolts, the screw, the nut and the instrument
panel brace sub±assy No.1.
13. REMOVE AIR CONDITIONER UNIT ASSY
(a) Disconnect the connectors and the clip.
(b) Remove the 2 nuts.
(c) PTC Heater model:
Remove the bolt.
(d) Remove the 2 bolts, the 2 nuts and the air conditioner unit
assy.
14. REMOVE AIR CONDITIONING RADIATOR ASSY
(a) Disconnect the clamp.