TOYOTA AVENSIS 2002 Repair Manual

I35349
I35350
I35350
I35349
±
HEATER & AIR CONDITIONER HEATER ASSY
55±101
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE HEATER ASSY
(a) Using pliers, grip the claws of the clip and slide the clip to
disconnect the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
(b) Disconnect the connector.
(c) Remove the 2 bolts and the heater assy.
7. INSTALL HEATER ASSY
(a) Install the heater assy with the 2 bolts. Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
(b) Connect the connector.
(c) Install the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
8.INSTALL FUEL FILTER ASSY (See page 11±82)
9.INSTALL AIR CLEANER ASSY (See page 11±82)
10.ADD ENGINE COOLANT (See page 16±44)
11.CHECK FOR ENGINE COOLANT LEAKS (See page 16±37)
12.CHECK FUEL LEAK (See page 11±56)

550ZI±01
I35437
Connector ºBº Wire harness side:
Connector ºAº
I36091
Connector ºBº From back side:
Connector ºAº 55±22
± HEATER & AIR CONDITIONERHOT GAS TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS TYPE POWER HEATER SYSTEM
ON±VEHICLE INSPECTION
1. INSPECT AIR CONDITIONING CONTROL ASSY
(a) Disconnect the connector from air conditioning control assy and inspect the connector on wire harness
side, as shown in the table.
Symbols (Terminal No.)Wiring ColorConditionSTD Voltage (V)
SOL+ (B17) ±
GND (B40)R ± W±BStart engine
Compressor: OperatePulse generation
MGV (B14) ±
GND (B40) (*1)R±Y ± W±BStart engine
Compressor: OperatePulse generation
HOT GAS IN (B22) ±
GND (B40) (*1)R±Y ± W±BIG SW: ON
Hot Gas SW: ONBattery positive voltage
If circuit is not as specified, try replacing the air conditioning control assy with a new one. If the circuit is not
as specified, inspect the circuits connected to the other parts.
(b) Connect the connector to air conditioning control assy and inspect wire harness side connector from
the back side, as shown in the table.
Symbols (Terminal No.)ConditionSpecified condition
HI (A4) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
HINo continuity
Continuity
M2 (A5) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
M2No continuity
Continuity
M1 (A6) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
M1No continuity
Continuity
GND (A1) ± Body groundIgnition switch ON
Turn blower dial: OFF
LONo continuity
Continuity

550ZJ±01
I36136
I32396
E
IN
IG
± HEATER & AIR CONDITIONERHOT GAS TYPE POWER HEATER SYSTEM
55±23
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT W/RECEIVER CONDENSER ASSY
(a) Apply voltage between terminals and check that the re-
frigerant passages switch.
2. INSPECT HETER SWITCH ASSY
(a) Check that the continuity to the follwing terminals.
Standard:
Heater switch conditionConnecting terminalsStandard value
ONIG ± INContinuity
OFFIG ± INNo continuity
ONIG ± EContinuity
OFFIG ± ENo continuity

550Z7±01
I35292
Sight Glass
55±24
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
REFRIGERANT
ON±VEHICLE INSPECTION
1. RHD AZ Engine series:
INSPECT REFRIGERANT VOLUME
(a) Observe the sight glass on the cooler refrigerant liquid
pipe A.
Test conditions:

All doors are fully open.

Temperature control dial is at ºMAX. COOLº.

Engine is running at 1,500 rpm.

Blower speed control switch is at ºHIº.

A/C switch is ON.
ItemSymptomAmount of refrigerantCorrective Actions
1Bubbles existInsufficient*
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
2No bubbles existEmpty, insufficient or excessiveRefer to 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage and repair if nec-
essary
(2) Add refrigerant until bubbles disappear
4Considerable temperature difference be-
tween compressor inlet and outletProper or excessiveRefer to 5 and 6
5Immediately after air conditioning is turned
off, refrigerant remains clearExcessive
(1) Discharge refrigerant
(2) Vacuum and supply proper amount of
new refrigerant
6
Immediately after air conditioning is turned
off, refrigerant foams and then becomes
clear
Proper±
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

I30081
0.5 (5.0)
0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Blower HI Zone
Blower LO Zone
MPa (kgf/cm
2) Pressure on HI
pressure side 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0)1.06 (10.9)
0.27 (2.85)
0.22 (2.25)
0.2 (2.1)
0.14 (1.5)1.2 (12.3)
1.25 (12.8)
1.32 (13.5)
± HEATER & AIR CONDITIONERREFRIGERANT
55±25
AVENSIS REPAIR MANUAL (RM1018E)
2. w/o Hot gas heater:
INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the manifold gauge pressure
when the following conditions are fullfilled.
Test conditions:

Engine has been warmed up.

All doors are fully open.

A/C switch is ON.

Engine is running at 1,500 rpm.

Air inlet mode selector switch is at RECIRE.

Temperature control dial is at ºMAX. COOLº.

Blower speed control switch is at ºHIº.

Temperature at the air inlet is 30 ± 35
C (86
± 95
F).
Gauge readings (Reference)

E50573
I22117
Condition : Air conditioning system periodically repeats proper and improper function. 55±26
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(1) When the refrigerant volume is proper:
Gauge reading:
Low pressure side:
0.15 ± 0.25 MPa (1.5 ± 2.5 kgf/cm
2)
High pressure side:
1.37 ± 1.57 MPa (14 ± 16 kgf/cm
2)
(2) When there is moisture in the refrigeration system:
SymptomProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side cycles between nor-
mal and vacuum
Moisture in refrigeration system
freezes at expansion valve orifice,
causing a temporary stop of cycle.
However, when it melts, normal
state is restored
Drier is overly saturated

Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace cooler drier
(2) Remove moisture in cycle by
repeatedly vacuuming
(3) Supply proper amount of new
refrigerant

I22118
Condition: Air conditioning system does not function effectively.
I22119
Condition: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±27
AVENSIS REPAIR MANUAL (RM1018E)
(3) When cooling is insufficient:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is low on both low and
high pressure sides

RHD AZ engine series:
Bubbles are seen through sight
glass continuously

Cooling performance is insuffi-
cient
Gas leakage in refrigeration sys-
tem
Insufficient refrigerant

Refrigerant leakage
(1) Check for gas leakage and re-
pair if necessary
(2) Supply proper amount of new
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leak-
age.
(4) When the circulation of the refrigerant is poor:
SymptomProbable causeDiagnosisCorrective Action

Pressure is low on both low and
high pressure sides

Frost exists on piping from con-
denser to A/C unit
Refrigerant flow is obstructed by
dirt in condenserCondenser is cloggedReplace condenser

I22120
Condition: Air conditioning system does not function. (Sometimes it may function)
I22121
Condition : Air conditioning system does not function effectively. 55±28
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(5) When the refrigerant does not circulate:
SymptomProbable causeDiagnosisCorrective Actions

Vacuum is indicated on low pres-
sure side, and extreamly low pres-
sure is indicated on high pressure
side

Frost or dew is seen on piping on
both sides of condenser or expan-
sion valve

Refrigerant flow is obstructed by
moisture or dirt in refrigeration sys-
tem

Refrigerant flow is obstructed by
gas leak from expansion valve
Refrigerant does not circulate
(1) Check the expansion valve
(2) Clean out dirt on expansion
valve by blowing air
(3) Replace condenser
(4) Vacuum and supply proper
amount of new refrigerant
(5) For gas leakage from expan-
sion valve, replace expansion
valve
(6) When the refrigerant is overcharged or cooling of
condenser is insufficient:
SymptomProbable causeDiagnosisRemedy

Pressure is extreamly high on
both low and high pressure sides

RHD AZ engine series:
No air bubbles are seen through
sight glass even when engine rpm
lowers

Excessive refrigerant

Cooling performance of con-
denser is insufficient
Excessive refrigerant

Cooling performance of con-
denser is insufficient
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check the amount of refrig-
erant and supply proper amount of
refrigerant

I22122
Condition: Air conditioning system does not function.
NOTE : These gauge indica-
tions occur when the refrigera-
tion system opens and the re-
frigerant is charged without
vacuuming.
I22123
Condition
: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±29
AVENSIS REPAIR MANUAL (RM1018E)
(7) When there is air in the refrigeration system:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and the high pressure
sides

The low pressure piping is too
hot to touch

RHD AZ engine series:
Bubbles can be seen through sight
glass
Air in refrigeration system

There is air in refrigeration sys-
tem

Vacuuming is insufficient
(1) Check it compressor oil is dirty
or insufficient
(2) Vacuum and supply new refrig-
erant
(8) When the expansion valve malfunctions:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and high pressure sides

Frost or dew is on piping on low
pressure side
Trouble with expansion valve

Excessive refrigerant in low
pressure piping

Expansion valve opened too
wide
Replace expansion valve

I22124
Condition
: Air conditioning system does not function. 55±30
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(9) When the compressor is defective:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and high pressure sides

Pressure is extreamly low on
high pressure side
Internal leak from compressor

Compression failure

Leakage from damaged valve or
broken sliding parts
Repair or replace compressor