air condition TOYOTA PRIUS 2001 Service Repair Manual

AC36D±01
I17963
I17964
± AIR CONDITIONINGCONDENSER FAN
AC±69
2001 PRIUS (RM778U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
3. REMOVE BRACKETS
(a) Remove the water hose from fan shroud.
(b) Remove the 5 bolts and 2 brackets.
4. REMOVE SUCTION AND DISCHARGE HOSES
(a) Remove the 2 bolts and disconnect the both hoses.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.
(b) Loosen the 2 nuts and remove the both hoses.
Torque:
Suction hose 32 N´m (330 kgf´cm, 24 ft´lbf)
Discharge hose 22 N´m (225 kgf´cm, 16 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O±rings with compressor oil and install them
to the tubes.

I17965
I17967
I17956
AC±70
± AIR CONDITIONINGCONDENSER FAN
2001 PRIUS (RM778U)
5. DISCONNECT RADIATOR HOSES FROM RADIATOR
AND CONDENSER MODULE
(a) Using pliers, grip the claw of the hose clip and slide the
clip along the hose.
(b) Disconnect the radiator hoses.
6. REMOVE CONDENSER FAN WITH FAN SHROUD
(a) Disconnect the 2 connectors.
(b) Remove the 2 bolts.
(c) Pull up the condenser fan with fan shroud until the it is re-
moved from the radiator and condenser module.
(d) Pull it downward to remove it.

AC36J±01
I17991
I18015
I18034
I18035
I18036 : Bulb
AC±76
± AIR CONDITIONINGHEATER CONTROL ASSEMBLY
2001 PRIUS (RM778U)
DISASSEMBLY
1. REMOVE CONTROL KNOBS
(a) Pull out the 5 control knobs.
(b) Remove the 3 nuts.
2. REMOVE MULTI DISPLAY & RADIO RECEIVER AS-
SEMBLY
Remove the 4 screws and multi display & radio receiver assem-
bly.
3. REMOVE A/C AMPLIFIER
(a) Remove the 12 screws and cover.
(b) Unlock the connector lock and pull out the flat harness
from center cluster module.
4. REMOVE BULBS
Using a screwdriver, turn the bulb to the left and pull out the
bulb.

I18037
± AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC±77
2001 PRIUS (RM778U)
5. REMOVE CLUSTER MODULE CIRCUIT
Remove the 6 screws and center cluster module.

AC36K±01
I18038 : Bulb
5
10
I07872
I17978
1
7
AC±78
± AIR CONDITIONINGHEATER CONTROL ASSEMBLY
2001 PRIUS (RM778U)
INSPECTION
1. INSPECT ILLUMINATION OPERATION
(a) Connect the positive (+) lead from the battery to terminal
5 and negative (±) lead to terminal 10, then check that the
illumination lights up.
If operation is not as specified, check the faulty bulb.
(b) Apply the tester as shown in the illustration to the test for
continuity.
If continuity exists, replace the heater control.
If no continuity exists, replace the bulb.
2. INSPECT INDICATOR OPERATION
Connect the positive (+) lead from the battery to terminal 1 and
negative (±) lead to terminal 7, then check that the illumination
light up.
If operation is not as specified, proceed next inspection.

I18039
1
3
2 Dry Cell Batteries
I18040
1
5
2 Dry Cell Batteries
I18043
1 15
2 Dry Cell Batteries
I18044
6 8 14
13
± AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC±79
2001 PRIUS (RM778U)
3. INSPECT F/R INDICATOR OPERATION
Connect the positive (+) lead from the two 1.5 V dry cell batter-
ies to terminal 1 and negative (±) lead to terminal 3, then check
that the F/R indicator lights up.
If operation is as specified, replace the A/C amplifier.
If operation is not as specified, replace the cluster module cir-
cuit.
4. INSPECT A/C INDICATOR OPERATION
Connect the positive (+) lead from the two 1.5 V dry cell batter-
ies to terminals 1 and negative (±) lead to terminal 5, then check
that the A/C indicator lights up.
If operation is as specified, replace the A/C amplifier.
If operation is not as specified, replace the cluster module cir-
cuit.
5. INSPECT MAX. A/C INDICATOR OPERATION
Connect the positive (+) lead from the two 1.5 V dry cell batter-
ies to terminal 1 and negative (±) lead to terminal 15, then check
that the MAX. A/C indicator lights up.
If operation is as specified, replace the A/C amplifier.
If operation is not as specified, replace the cluster module cir-
cuit.
6. INSPECT SWITCH CONTINUITY
Check the continuity between terminals while switch is pressed,
as shown in the chart.
SwitchTester connectionSpecified condition
F/R6 ± 13Below 500 W
A/C8 ± 13Below 500 W
MAX. A/C13 ± 14Below 500 W
If operation is not as specified, replace the cluster module cir-
cuit.

I180463 Dry Cell Batteries9
12 13
I180473 Dry Cell Batteries9
11 13
COOL
WARM
I180453 Dry Cell Batteries9
10 13 M1
M2
AC±80
± AIR CONDITIONINGHEATER CONTROL ASSEMBLY
2001 PRIUS (RM778U)
7. INSPECT MODE CONTROL DIAL OPERATION
(a) Check that the resistance between terminals 12 and 13
is approx. 3.0 kW.
(b) Connect the positive (+) lead from the three 1.5 V dry cell
batteries to terminal 9 and negative (±) lead to terminal
13.
(c) Connect the positive (+) lead from the tester to terminal
12 and negative (±) lead to terminal 13, then check that
the voltage at each dial position, as shown in the chart be-
low.
Dial positionSpecified condition
FACE "B/L0.7 V
B/L "FOOT2.0 V
FOOT "F/D3.2 V
F/D " DEF4.4 V
If operation is not as specified, replace the cluster module cir-
cuit.
8. INSPECT TEMPERATURE CONTROL DIAL OPERA-
TION
(a) Check that the resistance between terminals 11 and 13
is approx. 3.0 kW.
(b) Connect the positive (+) lead from the three 1.5 V dry cell
batteries to terminal 9 and negative (±) lead to terminal
13.
(c) Connect the positive (+) lead from the tester to terminal
11 and negative (±) lead to terminal 13.
(d) Gradually turn the dial from ºMAX. COOLº side to ºMAX.
WARMº side and check that the voltage increase from 4.5
to 0.4 V.
If operation is not as specified, replace the cluster module cir-
cuit.
9. INSPECT BLOWER SPEED CONTROL DIAL OPERA-
TION
(a) Check that the resistance between terminals 10 and 13
is approx. 3.0 kW.
(b) Connect the positive (+) lead from the three 1.5 V dry cell
batteries to terminal 9 and negative (±) lead to terminal
13.

± AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC±81
2001 PRIUS (RM778U)
(c) Connect the positive (+) lead from the tester to terminal
10 and negative (±) lead to terminal 13 then check that the
voltage at each dial position, as shown in the chart below.
Dial positionSpecified condition
OFF "AUTO1.45 V
AUTO "LO2.25 V
LO "M13.05 V
M1 " M23.85 V
M2 " H14.65 V
If operation is not as specified, replace the cluster module cir-
cuit.