TOYOTA AVENSIS 2003 Service Repair Manual

550ZA±01
I35278
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part


Compressor oil ND±OIL 8 or equivalent w/ receiver Condenser Assy
Liquid Tube Sub±assy A
Cooler Refrigerant Discharge Hose No.1
Cooler Dryer
Cap
1AZ±FSE:
O±ring


O±ring


5.4 (55, 47 in.
lbf)
5.4 (55, 47 in.
lbf)
2.9 (30, 25 in.
lbf)
w/o Hot gas heater:




±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
55±91
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS
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I35279
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part


Compressor oil ND±OIL 8 or equivalent w/ receiver Condenser Assy
Liquid Tube Sub±assy A
Cooler Refrigerant Discharge Hose No.1 O±ring

O±ring


w/ Hot gas heater:
5.4 (55, 47 in.
lbf)
O±ring


O±ring


5.4 (55, 47 in.
lbf)
O±ring


5.4 (55, 47 in.
lbf)
5.4 (55, 47 in.
lbf)5.4 (55, 47 in.
lbf)
O±ring


Discharge Tube Sub±assy
5.4 (55, 47 in.
lbf)
3.4 (35, 30 in.
lbf)
3.4 (35, 30 in.
lbf)
Discharge Tube
Discharge Tube
Refrigerant Filter
Magnet Valve Assy
55±92
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
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550ZB±01






I35836
w/o Hot gas heater:
w/ Hot gas heater:
I35335
I35336
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
55±93
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±91
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.REMOVE FRONT BUMPER COVER (See page 76±3)
3. DISCONNECT COOLER REFRIGERANT DISCHARGEHOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the w/ receiver condenser
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. DISCONNECT LIQUID TUBE SUB±ASSY A
(a) w/o Hot gas heater: Remove the bolt and disconnect the liquid tube sub±assy
A from the w/ receiver condenser assy.
(b) w/o Hot gas heater: Remove the O±ring from the liquid tube sub±assy A.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
(c) w/ LHD Hot gas heater: Disconnect the liquid tube sub±assy A assy from the liq-
uid tube sub±assy B.
(d) w/ LHD Hot gas heater: Remove the O±ring from the liquid tube sub±assy A.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
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I35337
I35336
I35339
I35340
55±94
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
sub±assy from the w/ receiver condenser assy.
(b) Remove 2 O±rings from the discharge tube sub±assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
6. REMOVE LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube sub±assy B from w/ receiver condenser assy.
(b) Remove the O±ring from the liquid tube sub±assy B.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
7. REMOVE HOOD LOCK ASSY
(a) Remove the 3 bolts and the hood lock assy.
8.REMOVE HIGH PITCHED HORN ASSY (See page 69±5)
9.REMOVE LOW PITCHED HORN ASSY (See page 69±4) 10. REMOVE HOOD LOCK SUPPORT BRACE
(a) Remove the 5 bolts and the hood lock support brace.
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I35341
I35342
I35343
I35344
I32993
14 mm
(0.55 in.)
Hexagon
WrenchModulator
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
55±95
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE W/RECEIVER CONDENSER ASSY
(a) Remove the bolt and the w/ receiver condenser assy.
12. REMOVE DISCHARGE TUBE (W/ HOT GAS HEATER)
(a) Remove the 2 bolts and the discharge tube.
13. REMOVE REFRIGERANT FILTER (W/ HOT GAS
HEATER)
(a) Disconnect the discharge tube and remove the refriger- ant filter.
14. R E M O V E M A G N E T VA LV E A S S Y ( W / H O T G A S HEATER)
(a) Remove the 4 bolts and the magnet valve assy.
15. REMOVE COOLER DRYER (W/O HOT GAS HEATER)
(a) 1AZ±FSE: Remove the 2 bolts and bracket.
(b) Using a hexagon wrench 14 mm (0.55 in.), remove the cap from the modulator.
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I32994
I32994

I32475
I32993
14 mm
(0.55 in.)
Hexagon
WrenchModulator
55±96
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using needle nose pliers, remove the cooler dryer.
16. REMOVE COOLER CONDENSER CUSHION NO.1
17. REMOVE COOLER CONDENSER CUSHION NO.2
18. REMOVE CONDENSER BRACKET COLLAR NO.1 19. INSTALL COOLER DRYER (W/O HOT GAS HEATER)
(a) Using needle nose pliers, install the new cooler dryer.
(b) Sufficiently apply compressor oil to the fitting surfaces ofthe O±ring.
Compressor oil: ND±OIL 8 or equivalent
(c) Using a hexagon wrench 14 mm (0.55 in.), install the new cap on the modulator.
Torque: 2.9 N
m (30 kgf
cm, 25 in.
lbf)
(d) 1AZ±FSE: Install the bracket with the 2 bolts.
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I35344
I35343
I35342
I35336
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
55±97
AVENSIS REPAIR MANUAL (RM1018E)
20. I N S TA L L M A G N E T VA LV E A S S Y ( W / H O T G A S
HEATER)
(a) Install the magnet valve assy with the 4 bolts.
Torque: 3.4 N
m (35 kgf
cm, 30 in.
lbf)
21. INSTALL REFRIGERANT FILTER (W/ HOT GAS HEATER)
(a) Install the refrigerant filter to the discharge tube.
22. INSTALL DISCHARGE TUBE (W/ HOT GAS HEATER)
(a) Install the discharge tube with the 2 bolts. Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
23. INSTALL LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the attached vinyl tape from the tube and the connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the liquid tube sub±assy B.
(d) Install the liquid tube sub±assy B on the w/ receiver con- denser assy with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
24. INSTALL DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the attached vinyl tape from the tube and the connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new 2 O±rings and
the fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the discharge tube sub±assy.
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I35337
I35335
I35336
55±98
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the discharge tube sub±assy on the w/ receiver condenser assy with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
25. INSTALL LIQUID TUBE SUB±ASSY A
(a) Remove the attached vinyl tape from the tube and the connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new O±ring and the
fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the liquid tube sub±assy A.
(d) w/o Hot gas heater: Install the liquid tube sub±assy A on the w/ receiver con-
denser assy core with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
(e) w/ LHD Hot gas heater: Install the liquid tube sub±assy A on the w/ receiver con-
denser assy with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
26. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1
(a) Remove the attached vinyl tape from the tube and the connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to the O±ring and the fit- ting surface of the hose joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the cooler refrigerant discharge hose No.1.
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I35837
w/o Hot gas heater:
w/ Hot gas heater:
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
55±99
AVENSIS REPAIR MANUAL (RM1018E)
(d) Install the cooler refrigerant discharge hose No.1 on the
w/ receiver condenser assy with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
27.INSTALL FRONT BUMPER COVER (See page 76±3)
28.CHARGE REFRIGERANT (See page 55±38) SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080), 07117±48130, 07117±48140
Specified amount: 440
30 g (15.51
1.06 oz.)
29.WARM UP ENGINE (See page 55±38)
30.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)
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550Z9±01
55±90
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
W/RECEIVER CONDENSER ASSY
ON±VEHICLE INSPECTION
1. INSPECT W/RECEIVER CONDENSER ASSY
(a) If the fin of the w/receiver condenser assy is dirty, clean it with water and dry it with compressed air.
NOTICE:
Do not damage the fin of the condenser assy.
(b) If the fin of the w/receiver condenser assy is bent, straighten it using\
a screwdriver or pliers.
2. INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT
(a) Using a halogen leak detector, check pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque of the joint.
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