TOYOTA AVENSIS 2003 Service Repair Manual

I22124
Condition: Air conditioning system does not function.
55±30
±
HEATER & AIR CONDITIONER REFRIGERANT
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
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± 50 g (± 1.76 oz.)
I37057
0.1 (1.0)0.4 (4.0)
0.3 (3.0)
0.2 (2.0) MPa (kgf/cm
2)
Pressure on low pressure side
Outside temperature
0
C ( F)
15 (59) 20 (68)
30 (86)
25 (77) 35 (95)
0 g (0 oz.)
(Standard)
+ 50 g (+ 1.76 oz.)
±
HEATER & AIR CONDITIONER REFRIGERANT
55±31
AVENSIS REPAIR MANUAL (RM1018E)
3. w/ Hot gas heater:
INSPECT REFRIGERANT VOLUME
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the the manifold gauge pres-
sure when these conditions are established.
Test conditions:

Engine is at idle.

Blower speed control switch is at ºHIº.

Temperature control dial is at ºMAX. COOLº.

Engine has been warmed up.

All doors are fully open.

Hood is fully open.

Air inlet mode selector damper is at RECIRE.

Air outlet damper is at FACE.

Outside temperature is 15 ± 35
C (59± 95

F).
(b) Check refrigerant volume according to the graph below.
RangeAmount of refrigerantCorrective actions
Except range belowInsufficient or excessive
Supply refrigerant until low
pressure become within the standard
50 g
(
1.76 oz.), or remove
refrigerant and then sup- ply proper amount of re-
frigerant
Standard
50 g
(
1.76 oz.)Proper±
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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)
55±32
±
HEATER & AIR CONDITIONER REFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
4. w/ Hot gas heater: INSPECT REFRIGE RANT 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 at idle.

Air inlet mode selector damper is at RECIRE.

Temperature control dial is at ºMAX. COOLº.

Blower speed control switch is at ºHIº.

Air outlet damper is at FACE.

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

Sunshine is shut off.
Gauge readings (Reference)
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E65563
I22117
Condition: Air conditioning system periodically repeats proper and improper functi\
on.
±
HEATER & AIR CONDITIONER REFRIGERANT
55±33
AVENSIS REPAIR MANUAL (RM1018E)
(1) When the refrigerant volume is proper:
Gauge reading:
Low pressure side:
0.28 ± 0.4 MPa (2.8 ± 4.0 kgf/cm
2)
High pressure side:
1.3 ± 1.6 MPa (13 ± 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 refrigerant filter 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 refrigerant filter 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
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I22118
Condition: Air conditioning system does not function effectively.
I22119
Condition : Air conditioning system does not function effectively.
55±34
±
HEATER & AIR CONDITIONER REFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(3) When cooling is insufficient:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is low on both low and
high pressure sides

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 unit
Refrigerant flow is obstructed by
dirt in condenserCondenser is cloggedReplace condenser
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I22120
Condition: Air conditioning system does not function. (Sometimes it may function)\
I22121
Condition : Air conditioning system does not function effectively.
±
HEATER & AIR CONDITIONER REFRIGERANT
55±35
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 refrig-
erant filter

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

Refrigerant filter is clogged
Refrigerant does not circulate
(1) Check the refrigerant filter
(2) Clean out dirt on refrigerant fil-
ter by blowing air
(3) Replace condenser
(4) Vacuum air and supply proper
amount of new refrigerant
(5) If refrigerant filter is damaged,
replace it
(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
Excessive refrigerant

Cooling performance of con-
denser is insufficient
Excessive refrigerant

Cooling performance of con-
denser is insufficient

Magnet valve assy is defective
(1) Clean condenser fins
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, vacuum and supply proper
amount of refrigerant
(4) If pressure is still high even af-
ter supplying refrigerant, replace
the magnet valve assy
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I22122
ConditionNOTE : These gauge indica-
tions occur when the refrigera-
tion system opens and the re-
frigerant is charged without
vacuuming.
: Air conditioning system does not function.
I22123
Condition : Air conditioning system does not function effectively.
55±36
±
HEATER & AIR CONDITIONER REFRIGERANT
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 sidesAir in refrigeration system

There is air in refrigeration sys-
tem

Vacuuming is insufficient(1) Check if compressor oil is dirty
or insufficient
(2) Vacuum air and supply new re-
frigerant
(8) When the refrigerant filter is defective:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
low pressure side

Pressure is extreamly high on
high pressure side
Trouble with refrigerant filterExcessive refrigerantReplace refrigerant filter
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I22124
Condition : Air conditioning system does not function.
I22123
Condition: Air conditioning system does not function effectively.
±
HEATER & AIR CONDITIONER REFRIGERANT
55±37
AVENSIS REPAIR MANUAL (RM1018E)
(9) When the compressor is defective:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
low pressure side

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

Compression failure

Leakage from damaged valve or
broken sliding parts
Replace or replace compressor
(10) When the magnet valve assy is defective:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
low pressure sideInternal leak from magnet valve
assyMagnet valve assy failureReplace magnet valve assy
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550Z8±01


I37091
Over charged
Mean
value
in proper
range
Hight
Pressure
Refrigerant Amount
30 g (
1.06 oz.)
Amount to be charged
Sub±cool system
RHD AZ Engine series:
55±38
±
HEATER & AIR CONDITIONER REFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Turn the A/C switch ON.
(b) Operate the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 min\
uites to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compresso\
r as
much as possible.
(c) Shut off the engine.
(d) Let the refrigerant gas out.
SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
2. CHARGE REFRIGERANT
(a) Using a vacuum pump, perform vacuuming.
(b) Charge refrigerant, HFC±134a (R134a).
Standard: 440
30 g (15.51
1.06 oz.)
SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
3. WARM UP ENGINE
4. INSPECT LEAKAGE OF REFRIGERANT
(a) Using a gas leak detector, check for leakage of the refrigerant.
NOTICE:
1CD±FTV Hot gas heater:
Since the system uses a refrigerant filter (fixed valve), sound of the refr\
igerant circulation (hissing
sound) can be heard for approx. 30 seconds after turning the A/C off. T\
his is merely a sound of bal-
ancing the low pressure with the high pressure, not a sound of abnormality.
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550YO±01
I34975N
m (kgf
cm, ft
lbf) : Specified torque Cooler Refrigerant Suction Hose No.1
Liquid Tube Sub±assy A
Cooler Refrigerant Discharge Hose No.1
9.8 (100, 87 in.
lbf)
5.4 (55, 47 in.
lbf)
5.4 (55, 47 in.
lbf)
9.8 (100, 87 in.
lbf)
LHD:
3ZZ±FE:
1ZZ±FE:
9.8 (100, 87 in.
lbf)
±
HEATER & AIR CONDITIONER REFRIGERANT LINE
55±39
AVENSIS REPAIR MANUAL (RM1018E)
REFRIGERANT LINE
COMPONENTS
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