55 - Hvac

551
HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM
AIR CONDITIONING SYSTEM

550IN01
PRECAUTION
1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION
AC2810
3.
AC2811
BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT
Wrong
Okay
6.
LO
HI
LO
HI
N11084
DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valves opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc.
2004 COROLLA (RM1037U)
Author :
Date :
1571
552
550IO01
ONVEHICLE INSPECTION
1. (a)
3
4 Low pressure side High pressure side ON (Continuity)
INSPECT PRESSURE SWITCH NO.1. Magnetic clutch control: Inspect pressure switch operation. (1) Set on the manifold gauge set. (2) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative () lead to terminal 1. (3) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch.
196 kpa 3,140 kpa 2 (2.0 kgf/cm2 28 psi) (132.0 kgf/cm 455 psi) OFF (No continuity) OFF (No continuity)
I30146
4 1,226 kpa (12.5 kgf/cm2 178 psi) ON OFF (Continuity) 1,520 kpa (No continuity) (15.5 kgf/cm2 220 psi)
I30291
Cooling fan control: Inspect pressure switch operation. (1) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative () lead to terminal 3. (2) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch.
(b)
2. COOLER COMPRESSOR ASSY W/MAGNETIC CLUTCH (a) Connect the positive (+) lead from the battery to terminal and the negative () lead to the body ground. (b) Check that the magnetic clutch energized. If operation is not as specified, replace the magnet clutch assy.
Author :
Date :
1572
553
550IP01
INSPECTION
1. (a)
+
COOLER THERMISTOR NO.1 Check resistance between terminals 1 and 2 of cooler thermistor No. 1 at each temperature, as shown in the chart. Resistance:
I32480
40 30 Resistance (k) 20 10 8 6 4 2 0
30 20 10
10
20
30 40
50 60
70
80
Temperature (_C)
I30145
If resistance value is not as specified, replace the sensor.
Author :
Date :
1573
554
2. (a)
COOLER AND ACCESSORY ASSY Inspect blower switch continuity.

Condition / Circuit OFF LO M1 M2 HI Tester connection 18 168 158 148 Specified condition No continuity Continuity Continuity Continuity Continuity
E37726
If continuity is not as specified, replace the air conditioner control assy. (b) Inspect illumination operation. Connect the positive (+) lead from the battery to terminal 2 and negative () lead to terminal 3 then check that the illuminations light up. If there is bulb not light up, replace the bulb. 3. COOLER SWITCH HOLE COVER (a) Inspect switch continuity. Check the continuity between terminals while switch is pressed, as shown in the chart.
Tester connection 25 Specified condition Continuity
E50533
If continuity is not as specified, replace the cooler switch. (b) Inspect illumination operation. Connect the positive (+) lead from the battery to terminal 4 and negative () lead to terminal 3 then check that the illuminations light up. If operation is not as specified, replace the cooler switch. (c) Inspect indicator operation. (1) Connect the positive (+) lead from the battery to terminal 2 and the negative () lead to terminal 1. (2) Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the cooler switch. (d) Inspect dimming operation (1) Connect the positive (+) lead from the battery to terminal 2 and the negative () lead to terminal 1 while press the switch. (2) Connect the positive (+) lead from battery to terminal 4 and then check that the indicator dims. If operation is not as specified, replace the cooler switch.
Author :
Date :
1574
555
4. (a)
BLOWER RESISTOR Measure resistance between terminals, as shown in the chart below.
Tester connection 12 13 14 Specified condition 1.398 1.605 0.465 0.535 3.069 3.531
If resistance is not as specified, replace the blower resistor.

E32877
5. (a)
BLOWER W/FAN MOTOR SUBASSY Connect the positive (+) lead from the battery to terminal 2 and negative () to terminal 1, then check that the motor operation smoothly. If operation is not as specified, replace the blower motor.
I30151
6.
HEATER BLOWER MOTOR RELAY ASSY

Condition constant Apply B+ between terminals 1 and 2. tester connection 12 34 35 Specified condition Continuity Continuity
If continuity is not as specified, replace the heater blower motor relay.

E32993
7.
MAGNETCLUTCH RELAY
Condition constant Apply B+ between terminals 1 and 2. tester connection 12 35 Specified condition Continuity Continuity
If continuity is not as specified, replace the magnetclutch relay.
I30152
Author :
Date :
1575
556
HEATER & AIR CONDITIONER REFRIGERANT
REFRIGERANT
550IQ01
1. (a) INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in witch the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established. Test conditions: S Temperature at the air inlet with the switch set at RECIRC is 30 35 C (86 95 F) S Engine running at 1500 rpm S Blower speed control switch at HI position S Temperature control dial at COOL position S A/C switch ON S Fully open doors
(1) Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 0.25 MPa (1.5 2.5 kgf/cm2) High pressure side: 1.37 1.57 MPa (14 16 kgf/cm2)
E50573
(2)
Condition : Periodically cools and then fails to cool
Moisture present in refrigeration system.
I22117
Symptom During operation, pressure on low pressure side sometimes become a vacuum and sometime normal
Probable cause Moisture in refrigerating system freezes at expansion valve orifice causing a temporary stop of cycle, however, when it melts, normal state is restored.
Diagnosis S Drier in oversaturected state S Moisture in refrigerating system freezes at expansion valve orifice and blocks circulation of refrigerant
Remedy (1) Replace condenser (2) Remove moisture in cycle by repeatedly evacuating air (3) Supply proper amount of new refrigerant
Author :
Date :
1576
557
(3)
Condition: Cooling system does not function eftectively.
Insufficient cooling
I22118
Symptom
Probable cause
Diagnosis
Corrective Actions (1) Check for gas leakage and repair if necessary (2) Supply proper amount of new refrigerant (3) If indicated pressure value is close to a 0 when connected to gauge, create the vacuum after inspecting and repairing location of leak
S Pressure low on both low and high pressure sides S Insufficient cooling performance
Gas leakage in refrigeration system
S Insufficient refrigerant S Refrigerant leaking
(4)
Condition: Cooling system close not function effectively.
Poor circulation of refrigerant
I22119
Symptom S Pressure low on both low and high pressure sides S Frost on pipe from condenser to unit
Probable cause Refrigerant flow obstructed by dirt in receiver
Diagnosis
Corrective Action
Receiver clogged
Replace condenser
Author :
Date :
1577
558
(5)
Refrigerant does not circulate
Condition: Cooling system does not function. (Sometimes it way function)
I22120
Symptom
Probable cause
Diagnosis
Corrective Actions (1) Check expansion valve (2) Clean out dirt in expansion valve by air blowing (3) Replace condenser (4) Evaporate air and supply proper amount of new refrigerant. (5) For gas leakage from expansion valve, replace expansion valve
S Vacuum indicated on low pressure side, very low pressure indicated on high pressure side S Frost or dew seen on piping before and after receiver/ drier or expansion valve
S Refrigerant flow obstructed by moisture or dirt in refrigerating system Refrigerant does not circulate S Refrigerant flow obstructed by gas leaked from expansion valve
(6)
Refrigerant overcharged or insufficient cooling of condenser
Condition: Cooling system does not function dftectively.
I22121
Symptom
Probable cause
Diagnosis S Excessive refrigerant in cycletoo much refrigerant supplied S Condenser cooling insufficientcondenser fins clogged at cooling fan
Remedy (1) Clean condenser (2) Check cooling fan with cooling fan motor operation (3) If (1) and (2) are in normal state, check amount of refrigerant and supply proper amount of refrigerant
S Pressure too high on both low and high pressure sides
S Unable to develop sufficient performance due to excessive use of refrigerating system S Insufficient cooling of condenser
Author :
Date :
1578
559
(7)
Condition: Cooling system does not function.
Air present in refrigeration system
NOTE : These gauge indications are shown when the refrigerating system has been opens and the refrigerant charged without vacuum purging.
I22122
Symptom S Pressure too high on both low and high pressure sides S The low pressure piping too hot to the touch
Probable cause
Diagnosis S Air present in refrigerating system S Insufficient vacuum purging
Corrective Actions (1) Check compressor oil to see if it is see if it is dirty or insufficient (2) Evacuate air and supply new refrigerant
Air entered in refrigerating system
(8)
Condition: Refrigerant functions insufficient.
Expansion valve improperly
I22123
Symptom S Pressure too high on both low and high pressure sides S Frost or large amount of dew on piping on low pressure side
Probable cause
Diagnosis S Excessive refrigerant in low pressure piping S Expansion valve opened too wide
Corrective Actions
Trouble in expansion valve
Check expansion valve
Author :
Date :
1579
5510
(9)
Condition : Refrigerant is not effective.
Defective compression compressor
I22124
Symptom S Pressure too high on low high pressure sides S Pressure too low to on high pressure side
Probable cause
Diagnosis S Compression failure S Leakage from valve damaged or broken sliding parts
Corrective Actions
Internal leak in compressor
Repair or replace compressor
Gauge readings (Reference)
Pressure on low pressure side MPa (kgf/cm2)
0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.9) 0.3 (3.0) 0.27 (2.85) 0.2 (2.0) 0.22 (2.25) 0.2 (2.1) 1.25 (12.8) 0.14 (1.5) 1.32 (13.5) Pressure on HI pressure side MPa (kgf/cm2)
I30081
1.2 (12.3) Blower LO Zone
0.5 (5.0)
1.0 (10.0)
1.5 (15.0)
2.0 (20.0)
Author :
Date :
1580
5511
550IR01
REPLACEMENT
1. (a) (b) DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Turn the A/C switch ON. Operating the cooler compressor at the engine rpm of approx. 1000 for 5 to 6 min., circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Let the refrigerant gas out. SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) CHARGE REFRIGERANT Using a vacuum pump, perform a vacuum pumping. Supply refrigerant, HFC134a (R134a). Standard: 490 " 30 g (17.28 " 1.06 oz.) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080), 0711748130, 0711748140 WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant.
(c) (d)
2. (a) (b)
3. 4. (a)
Author :
Date :
1581
5512
HEATER & AIR CONDITIONER REFRIGERANT LINE
REFRIGERANT LINE
550IS01
COMPONENTS
9.8 (100, 87 in.lbf)
Cooler Refrigerant Liquid Pipe A

5.4 (55, 49 in.lbf)
Cooler Refrigerant Suction Hose No. 1
9.8 (100, 87 in.lbf)
Discharge Hose Subassy
Nm (kgfcm, ftlbf) : Specified torque

I32213
Author :
Date :
1582
5513
HEATER & AIR CONDITIONER HEATER CONTROL & ACCESSORY ASSY
HEATER CONTROL & ACCESSORY ASSY

550IT01
REPLACEMENT
1. 2. REMOVE CONSOLE PANEL UPPER (See page 7110) REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page 7110)
3. (a)
REMOVE HEATER CONTROL & ACCESSORY ASSY Release the 2 fitting claws and pull out the heater control & accessory assy.
2 Claws
I32427
Using a screwdriver, open the claw of the cable clamp and disconnect the defroster damper control cable. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse. HINT: Tape the screwdriver tip before use.
I32428
(b)
(c)
I32429
I32430
Using a screwdriver, open the claw of the cable clamp and disconnect the air mix damper control cable. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse. HINT: Tape the screwdriver tip before use. (d) Disconnect the connector, remove the heater control & accessory assy. 4. INSTALL HEATER CONTROL & ACCESSORY ASSY (a) Install the inner cable end of the air mix damper control cable to the heater control lever. (b) Install the outer cable of the air mix damper control cable to the cable clamp. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse.
Author :
Date :
1583
5514
HEATER & AIR CONDITIONER HEATER CONTROL & ACCESSORY ASSY
HINT:
S
Operating the heater control knob and check that it properly stops at both ends of MAX. COOL and MAX. HOT and no recoil is identified. Check that the outer cable should not be disengaged (moved) from the heater control & accessory assy when the cable is pulled.
(c)
I32431
Install the inner cable end of the defroster damper control cable to the heater control lever. (d) Install the outer cable of the defroster damper control cable to the cable clamp. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse. HINT: S Operating the heater control knob and check that it properly stops at both ends of FACE and DEF and no recoil is identified. S Check that the outer cable should not be disengaged (moved) from the heater control & accessory assy when the cable is pulled. (e) Connect the connector, install the heater control & accessory assy.
Author :
Date :
1584
5515
HEATER & AIR CONDITIONER AIR CONDITIONING UNIT ASSY
AIR CONDITIONER UNIT ASSY

550IU01
COMPONENTS
Defroster Nozzle Assy
Heater to Register Duct No.1 Instrument Panel to Cowl Brace Center
Heater to Register Duct No.2
Instrument Panel Reinforcement
Instrument Panel LWR Insert LH

9.8 (100, 87 in.lbf)
Instrument Panel Brace Subassy No.1
w/ Cold Area: Air Duct Rear No.4
Air Duct No.2

9.8 (100, 87 in.lbf)
Air Duct No.1
Air Conditioner Unit Assy
Air Duct Rear No.3
Nm (kgfcm, ftlbf) : Specified torque

I32531
Author :
Date :
1585
5516
Damper Servo Subassy
Air Conditioning Tube Assy

3.5 (35, 30 in.lbf)
Air Filter z Cooler Evaporator Subassy No.1 ORing
ORing
ORing Cooler Expansion Valve Air Filter Case
Blower w/ fan Motor Subassy
Blower Resistor Cooler Thermistor No.1 Cooler Unit Drain Hose No.1
Heater Radiator Unit Subassy
Heater Piping Cover
Nm (kgfcm, ftlbf) : Specified torque z Compressor Oil NDOIL 8 or equivalent Nonreusable Part
I32532
Author :
Date :
1586
5517
550IV02
OVERHAUL
HINT: COMPONENT: See page 5515 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 5511) SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080)
2. (a)
DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 Install SST to piping clamp. SST 0987000015
SST
HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label.
I03838
Push
Pull
(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, then remove the piping clamp with SST. (d) Remove the piping clamp from SST.
SST Release Lever Disconnect the tube using hand
I03839
Screw Driver
(e) Disconnect the cooler refrigerant suction hose No. 1. NOTICE: S Do not use tools like screwdriver to remove the tube. S Cap the open fittings immediately to keep moisture or dirt out of the system.
I06919
3.
DISCONNECT COOLER REFRIGERANT LIQUID PIPE A SST 0987000015
HINT: Disconnect in the same way as the cooler refrigerant suction hose No. 1.
Author :
Date :
1587
5518
4. (a)
DISCONNECT HEATER INLET WATER HOSE Using pliers, grip the claws of clip and slide the clip and disconnect the heater inlet water hose.
I32426
5. DISCONNECT HEATER OUTLET WATER HOSE HINT: Disconnect in the same way as the heater inlet water hose. 6. REMOVE INSTRUMENT PANEL SUBASSY LOWER (See page 7110) HINT: Refer to the instructions for removal of the instrument panel subassy lower.
7. (a)
REMOVE INSTRUMENT PANEL LWR PAD INSERT LH Remove the 3 screws and instrument panel LWR pad insert LH.
I32436
8.
(a) HINT: Take up the floor carpet as small as the instrument panel brace subassy No. 1 can be removed.
REMOVE INSTRUMENT PANEL BRACE SUBASSY NO.1 Remove 2 clips and take up the floor carpet.
I32432
(b)
Remove the clamp and floor shift parking lock cable assy.
Clamp
I32437
Author :
Date :
1588
5519
(c) (d)
Remove the screw. Remove the bolt, nut and instrument panel brace sub assy No. 1.
I32438
9. (a)
REMOVE AIR DUCT NO.1 Release the 2 fitting claws, remove the air duct No. 1.
2 Claws
I32439
10. (a) (b)
REMOVE AIR DUCT NO.2 Remove the screw. Release the 2 fitting claws, remove the air duct No. 2.
2 Claws
I32440
11. (a)
REMOVE AIR DUCT REAR NO.3 (W/ COLD AREA) Release the 6 fitting claws, remove the air duct rear No.3.
6 Claws
I32433
12. REMOVE AIR DUCT REAR NO.4 (W/ COLD AREA) (a) Remove 2 clips and take up the floor carpet. HINT: Take up the floor carpet as small as the air duct rear No.4 can be removed.
I32434
Author :
Date :
1589
5520
(b)
Release the 6 fitting claws, remove the air duct rear No.4.
6 Claws
I32435
13. (a)
REMOVE HEATER TO REGISTER DUCT NO.2 Remove the 2 clips and heater to register duct No. 2.
I32441
14. (a)
REMOVE HEATER TO REGISTER DUCT NO.1 Remove the 2 clips and heater to register duct No. 1.
I32442
15. (a)
REMOVE DEFROSTER NOZZLE ASSY Release the 3 fitting claws, remove the defroster nozzle assy.
3 Claws
I32443
16.
Clamp
I32526
DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUBASSY (a) Disconnect the outer cable from the clamp. (b) Disconnect the inner cable and defroster damper control cable subassy. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse.
Author :
Date :
1590
5521
17.
Clamp
I32527
DISCONNECT AIRMIX DAMPER CONTROL CABLE SUBASSY (a) Disconnect the outer cable from the clamp. (b) Disconnect the inner cable and air mix damper control cable subassy. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse. 18. DISCONNECT ECM (a) Remove the 2 bolts and disconnect the ECM. NOTICE: S Do not apply excessive force to the connecter of the ECM. S Do not give any impact to the ECM.
I32534
19. (a)
REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER Remove the 2 nuts and instrument panel to cowl brace center.
I32446
20. (a)
DISCONNECT STEERING COLUMN ASSY Disconnect the connector, remove the 2 clamps.
2 Clamps
I32444
(b)
Remove the 3 bolts, disconnect the steering column assy.
I32445
Author :
Date :
1591
5522
21. (a)
REMOVE INSTRUMENT PANEL REINFORCEMENT Remove the 8 screws and 2 earth wires from the instrument panel reinforcement.
I32447
(b)
Disconnect the 6 clamps and wire harness.
6 Clamps
I32448
Author :
Date :
1592
5523
(c)
Remove the 6 bolts and instrument panel reinforcement.
I32449
22. (a)
Lock Point
REMOVE AIR CONDITIONER UNIT ASSY Release the 2 fitting claws, disconnect the connector holder.
HINT: Release the claw while pressing the lock part in the arrow direction.
2 Claws
I32485
(b)
Disconnect the connector from the blower w/ fan motor subassy.
I32486
(c)
Disconnect the connector from the damper servo sub assy.
I32487
Author :
Date :
1593
5524
(d)
Disconnect the connector from the cooler thermistor No. 1.
I32488
(e)
Remove the 4 nuts, bolt and air conditioner unit assy.
I32489
23. (a)
REMOVE AIR FILTER CASE Release the 2 fitting claws, remove the air filter case.
2 Claws
I32490
24. REMOVE AIR FILTER (a) Remove the air filter from the air conditioner unit assy. HINT: Removing only the glove compartment door assy makes it possible and install the air filter.
I32491
25. REMOVE DAMPER SERVO SUBASSY (a) Remove the 2 screws and damper servo subassy. HINT: Removing only instrument panel subassy upper and heater to register duct No. 1 makes it possible and install the damper servo subassy.
I32492
Author :
Date :
1594
5525
26. REMOVE BLOWER W/FAN MOTOR SUBASSY (a) Remove the 3 screws and blower w/ fan motor subassy. HINT: Removing only the ECM makes it possible and install the blower w/fan motor subassy.
I32493
27. REMOVE BLOWER RESISTOR (a) Disconnect the connector. (b) Remove the 2 screws and blower resistor. HINT: Removing only the ECM makes it possible and install the blower resistor.
I32494
28. (a)
REMOVE HEATER PIPING COVER Release the 3 fitting claws, remove the heater piping cover.
3 Claws
I32495
29. (a)
REMOVE HEATER RADIATOR UNIT SUBASSY Release the 3 fitting claws, remove the heater piping clamp and heater radiator unit subassy
3 Claws
I32496
Author :
Date :
1595
5526
30. (a)
REMOVE COOLER THERMISTOR NO.1 Remove the clamp.
(b)
Release the fitting claw, remove the 2 screws and heater case.
Clamp
I32665
Claw
I32497
(c)
Release the fitting claw, remove the 5 screws and heater case.
Claw
I32498
Author :
Date :
1596
5527
(d)
Remove the cooler thermistor No. 1 from the cooler evaporator subassy No. 1.
I32666
31. (a) (b)
REMOVE AIR CONDITIONING TUBE ASSY Remove the cooler evaporator assy from the heater case. Remove the packing.
I32500
(c) (d)
Using a hexagon wrench 5.0 mm (0.20 in.), remove the 2 hexagon bolts and air conditioning tube assy. Remove the 2 Orings from the air conditioning tube assy.
I32501
32. (a) (b)
REMOVE COOLER EXPANSION VALVE Remove the cooler expansion valve from the cooler evaporator subassy No. 1. Remove the 2 Orings from the cooler evaporator sub assy No. 1.
I32502
HINT: Removing only instrument panel subassy upper, heater to register duct No. 1 and heater case makes it possible and install the cooler expansion valve.
33. 34.
REMOVE COOLER EVAPORATOR SUBASSY NO.1 REMOVE COOLER UNIT DRAIN HOSE NO.1
Author :
Date :
1597
5528
35. (a)
(b)
INSTALL COOLER EXPANSION VALVE Lubricate 2 new Orings with compressor oil and install them to the cooler expansion valve. Compressor oil: NDOIL 8 or equivalent Install the cooler expansion valve from cooler evaporator subassy No. 1.
I32502
36. (a)
(b)
INSTALL AIR CONDITIONING TUBE ASSY Lubricate 2 new Orings with compressor oil and install them to the air conditioning tube assy. Compressor oil: NDOIL 8 or equivalent Using a hexagon wrench 5.0 mm (0.20 in.), install the air conditioning tube assy with the 2 hexagon bolts. Torque: 3.5 Nm (35 kgfcm, 30 in.lbf)
I32501
(c) Install the packing. HINT: Securely attach so that the gap in the packing will not be mode. (d) Install the cooler evaporator assy to the heater case.
I32500
50 mm (2.0 in.)
37. (a)
INSTALL COOLER THERMISTOR NO.1 Install the cooler thermistor No. 1 at the shown position on the illustration.
45 mm (1.77 in.)
I32503
Author :
Date :
1598
5529
(b)
Install the heater case with the claw and 5 screws.
Claw
I32498
(c)
Install the heater case with the claw and 2 screws.
Claw
I32497
38. (a)
INSTALL AIR FILTER Install the air filter to the air conditioner unit assy.
I32504
Author :
Date :
1599
5530
(1) (2)
(2)
INSTALL AIR CONDITIONER UNIT ASSY Install the air conditioner unit assy with the 4 nuts and bolt. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf) NOTICE: Tighten the nuts and bolt in following order shown in the illustration to install the air conditioner unit assy.
39. (a)
(4) (3)
I32489
(b)
Connect the connector to the cooler thermistor No. 1.
I32488
(c)
Connect the connector to the damper servo subassy.
I32487
(d)
Connect the connector to the blower w/ fan motor sub assy.
I32486
(e)
Lock Point
Install the 2 fitting claws, connect the connector holder.
2 Claws
I32485
Author :
Date :
1600
5531
INSTALL ECM Install the ECM with the 2 bolts. Torque: 3.0 Nm (30 kgfcm, 26 in.lbf) NOTICE: S Do not apply excessive force to the connecter of the ECM. S Do not give any impact to the ECM.
I32534
40. (a)
41. 42.
INSTALL INSTRUMENT PANEL SUBASSY LOWER (See page 7110) INSTALL HEATER CONTROL & ACCESSORY ASSY (See page 5513)
FACE
DEF
I32528
INSTALL DEFROSTER DAMPER CONTROL CABLE SUBASSY (a) Set the arm in FACE position. (b) Install the inner cable end to the control lever with the arm in FACE position. (c) Install the outer cable to the cable clamp while slightly pressing it in the direction of the arrow. NOTICE: S Be careful not to bend the cable wire. S If the cable wire bends, the heater control & accessory assy operationality becomes worse. HINT: Operating the mode control lever, check that it properly stops at both ends of FACE and DEF and no recoil is identified. 44.
43.
45. 46.
INSTALL AIRMIX DAMPER CONTROL CABLE SUBASSY (a) Set the arm in MAX. COOL position. (b) Install the inner cable end to the control lever with the arm in MAX. COOL position. (c) Install the outer cable to the cable clamp while slightly MAX. pressing it in the direction of the arrow. COOL MAX. HOT NOTICE: S Be careful not to bend the cable wire. I32529 S If the cable wire bends, the heater control & accessory assy operationality becomes worse. HINT: Operating the temperature control lever, check that it properly stops at both ends of MAX. COOL and MAX. HOT and no recoil is identified. REMOVE HEATER CONTROL & ACCESSORY ASSY (See page 5513) INSTALL INSTRUMENT PANEL SUBASSY UPPER (See page 7110)
Author :
Date :
1601
5532
Marking
47. (a)
90_
INSTALL HEATER OUTLET WATER HOSE Using pliers, grip the claws of clip and slide the clip and connect the heater outlet water hose. NOTICE: S The clip is installing so that the projection of the clip may go into the 90_ to a direction position. S Marking of hose is installed upward by vehicle.
I32525
48. INSTALL HEATER INLET WATER HOSE HINT: Connect in the same way as the heater outlet water hose.
49.
Connect Gap Wrong
(a)
(b)
INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Lubricate a new Oring with compressor oil and install them to the hose. Compressor oil: NDOIL 8 or equivalent Install the cooler refrigerant suction hose No. 1 and piping clamp.
I06878
HINT: After connection, check the fitting for claw of the piping clamp.
50. (a)
(b) HINT: After connection, check the fitting for claw of the piping clamp. 51. ADD COOLANT (See page 167) 52. CHECK ENGINE COOLANT LEAK (See page 161) 53. CHARGE REFRIGERANT (See page 5511) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080), 0711748130, 0711748140 Specified amount: 490 " 30 g (17.28 " 1.06 oz.) 54. WARM UP ENGINE 55. INSPECT LEAKAGE OF REFRIGERANT (See page 5511)
INSTALL COOLER REFRIGERANT LIQUID PIPE A Lubricate a new Oring with compressor oil and install them to the pipe. Compressor oil: NDOIL 8 or equivalent Install the cooler refrigerant liquid pipe A and piping clamp.
Author :
Date :
1602
5533
HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY
COOLER COMPRESSOR ASSY

550IZ01
COMPONENTS
Magnet Clutch Assy
Cooler Compressor Assy z z Snap Ring Snap Ring
18 (183, 13)
Magnet Clutch Washer
Nm (kgfcm, ftlbf) : Specified torque z NonReusable part
I32420
Author :
Date :
1603
5534
550J001
REPLACEMENT
HINT: COMPONENTS: See page 5533 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 5511) SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080)
2.
I32458
DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the bolt and disconnect the cooler refrigerant suction hose No. 1 from the compressor and magnetic clutch. (b) Remove the Oring from the cooler refrigerant suction hose No. 1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 3. DISCONNECT DISCHARGE HOSE SUBASSY (a) Remove the bolt and disconnect the discharge hose sub assy from the compressor and magnetic clutch. (b) Remove the Oring from the discharge hose subassy. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
I32459
4. 5.
REMOVE ENGINE UNDER COVER RH REMOVE FAN AND GENERATOR V BELT (See page 144)
6. (a) (b)
REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector. Remove the 3 bolts and compressor and magnetic clutch.
I32421
7. (a)
REMOVE MAGNET CLUTCH ASSY Place the compressor and magnetic clutch in vise.
Author :
Date :
1604
5535
(b) (c)
Using a vise pliers, hold the magnet clutch hub. Remove the bolt, magnet clutch hub and magnet clutch washer.
I32422
(d) (e)
Using a snap ring expander, remove the snap ring and magnet clutch rotor. Remove the screw, disconnect the connector.
E37091
(f)
Using a snap ring expander, remove the snap ring and magnet clutch starter.
E50116
8.
REMOVE COOLER COMPRESSOR ASSY
9. (a)
INSTALL MAGNET CLUTCH ASSY Matching the parts shown in the illustration, install the magnet clutch starter.
I32460
Author :
Date :
1605
5536
(b) (c)
Using a snap ring expander, install a new snap ring with the chamfered side facing up. Install the screw, connect the connector.
I32461
(d)
Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. (e) Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch washers used before disassembly.
I31582
(f)
Using a vise pliers, hold the magnet clutch hub and install the bolt. Torque: 18 Nm (183 kgfcm, 13 ftlbf)
I32423
10. (a) (b)
I32424
INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the magnet clutch hub. Connect the battery positive lead to the terminal 1 of magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance. Standard clearance: 0.35 0.60 mm (0.013 0.023 in.) If the measured value is out of the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnet clutch washers.
Author :
Date :
1606
5537
11. (a)
INSPECT COMPRESSOR OIL When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.) ) (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE: S When checking the compressor oil level, observe the precautions on the cooler removal/installation. S Because compressor oil remains in the pipes of the vehicle, if a new compressor and magnetic clutch is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. S If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage. S Be sure to use NDOIL8 for compressor oil.
(1) (2) (3)

I32421
INSTALL COMPRESSOR AND MAGNETIC CLUTCH Install the compressor and magnetic clutch with the 3 bolts. Toque: 29 Nm (295 kgfcm, 21 ftlbf) NOTICE: Tighten the bolts in following order shown in the illustration to install the compressor and magnetic clutch. (b) Connect the connector.
12. (a)
13. (a) (b)
(c)
INSTALL DISCHARGE HOSE SUBASSY Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new Oring and fit surface of the compressor and magnetic clutch. Compressor oil: NDOIL8 or equivalent Install a Oring to the discharge hose subassy.
(d)
Install the discharge hose subassy to the compressor and magnetic clutch with the bolt. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf)
I32459
Author :
Date :
1607
5538
14. (a) (b)
(c)
INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new Oring and fit surface of the compressor and magnetic clutch. Compressor oil: NDOIL8 or equivalent Install a Oring to the cooler refrigerant suction hose No. 1.
(d)
Install the cooler refrigerant suction hose No. 1 to the compressor and magnetic clutch with the bolt. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf)
I32458
15.
16. 17.
CHARGE REFRIGERANT (See page 5511) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080), 0711748130, 0711748140 Specified amount: 490 " 30 g (17.28 " 1.06 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 5511)
Author :
Date :
1608
5539
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
W/RECEIVER CONDENSER ASSY

550IW01
1. INSPECT W/RECEIVER CONDENSER ASSY (a) If a fin of the w/receiver condenser assy is dirty, clean it with water and dry it with compressor air. NOTICE: Do not damage the fin of the w/receiver condenser assy. (b) If a fin of the w/receiver condenser assy is bent, make it straight using a screwdriver or pliers. 2. INSPECT W/RECEIVER CONDENSER ASSY 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.
Author :
Date :
1609
5540
550IX01
COMPONENTS
9.8 (100, 87 in.lbf)
z ORing
z ORing W/receiver Condenser Assy

5.4 (54, 48 in.lbf)
Cooler Dryer
z ORing
Cap
2.9 (29, 25 in.lbf)
Nm (kgfcm, ftlbf) : Specified torque Compressor Oil NDOIL 8 or equivalent z Nonreusable part Author : Date :
I32505
1610
5541
550IY01
OVERHAUL
HINT: COMPONENTS: See page 5540 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 5511) SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080)
2.
I31967
DISCONNECT COOLER REFRIGERANT LIQUID PIPE A (a) Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the w/receiver condenser assy. (b) Remove the Oring from the cooler refrigerant liquid pipe A. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 3. (a) DISCONNECT DISCHARGE HOSE SUBASSY Remove the bolt and discharge hose subassy from the w/receiver condenser assy. (b) Remove the Oring from the discharge hose subassy. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
I32450
4. (a)
REMOVE W/RECEIVER CONDENSER ASSY Remove the 2 bolts and 2 radiator upper supports.
I32451
(b) (c)
Remove the 2 bolts. Slide the upper part of the radiator assy rearward to remove the w/receiver condenser assy.
I32452
Author :
Date :
1611
5542
5. (a)
14 mm (0.55 in.) Hexagon Wrench Modulator
I30086
REMOVE COOLER DRYER Using a socket hexagon wrench 14 mm (0.55 in.), remove the cap from the modulator.
(b)
Remove the Oring from the cap.
E55408
I32475
(c) 6. (a)
Using pliers, remove the cooler dryer. INSTALL COOLER DRYER Using pliers, install the cooler dryer.
E50386
(b) (c)
Install the new Oring to the cap. Sufficiently apply compressor oil to the fit surfaces of the Oring and the cap. Compressor oil: NDOIL 8 or equivalent
E55408
(d)
Using a socket hexagon wrench 14 mm (0.55 in.), install the cap to the modulator. Torque: 2.9 Nm (29 kgfcm, 25 in.lbf)
14 mm (0.55 in.) Hexagon Wrench Modulator

I30086
Author :
Date :
1612
5543
7. (a)
INSTALL W/RECEIVER CONDENSER ASSY Install the w/receiver condenser assy with the 2 bolts. Torque: 9.8 Nm (100 kgfcm, 87 in.lbf)
I32453
(b)
Install the 2 radiator upper supports with the 2 bolts.
8. (a)
I32451
(b)
(c)
INSTALL DISCHARGE HOSE SUBASSY Remove the attached vinyl tape from the hose and connecting part of the w/receiver condenser assy. Sufficiently apple compressor oil to the new Oring and hose joint. Compressor oil: NDOIL 8 or equivalent Install a Oring to the discharge hose subassy.
(d)
Install the discharge hose subassy to the w/receiver condenser assy with the bolt. Torque: 5.4 Nm (54 kgfcm, 48 in.lbf)
9. (a)
I32450
(b)
(c)
INSTALL COOLER REFRIGERANT LIQUID PIPE A Remove the attached vinyl tape from the pipe and w/receiver condenser assy. Sufficiently apple compressor oil to the new Oring and pipe joint. Compressor oil: NDOIL 8 or equivalent Install a Orings to the cooler refrigerant liquid pipe A.
(d)
Install the cooler refrigerant liquid pipe A to the w/receiver condenser assy with the bolt. Torque: 5.4 Nm (54 kgfcm, 48 in.lbf)
I31967
Author :
Date :
1613
5544
10.
11. 12.
CHARGE REFRIGERANT (See page 5511) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080), 0711748130, 0711748140 Specified amount: 490 " 30 g (17.28 " 1.06 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 5511)
Author :
Date :
1614

55 - Hvac

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551

HEATER & AIR CONDITIONER AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM

2004 COROLLA (RM1037U)

4 Low pressure side High pressure side ON (Continuity)

2004 COROLLA (RM1037U)

If resistance value is not as specified, replace the sensor.

2004 COROLLA (RM1037U)

COOLER AND ACCESSORY ASSY Inspect blower switch continuity.

2004 COROLLA (RM1037U)

If resistance is not as specified, replace the blower resistor.

HEATER BLOWER MOTOR RELAY ASSY

If continuity is not as specified, replace the heater blower motor relay.

If continuity is not as specified, replace the magnetclutch relay.

2004 COROLLA (RM1037U)

Moisture present in refrigeration system.

2004 COROLLA (RM1037U)

Gas leakage in refrigeration system

S Insufficient refrigerant S Refrigerant leaking

Poor circulation of refrigerant

Probable cause Refrigerant flow obstructed by dirt in receiver

2004 COROLLA (RM1037U)

Refrigerant does not circulate

Condition: Cooling system does not function. (Sometimes it way function)

Refrigerant overcharged or insufficient cooling of condenser

Condition: Cooling system does not function dftectively.

S Pressure too high on both low and high pressure sides

2004 COROLLA (RM1037U)

Air present in refrigeration system

Diagnosis S Air present in refrigerating system S Insufficient vacuum purging

Air entered in refrigerating system

Expansion valve improperly

Trouble in expansion valve

Check expansion valve

2004 COROLLA (RM1037U)

Defective compression compressor

Internal leak in compressor

Repair or replace compressor

Gauge readings (Reference)

Pressure on low pressure side MPa (kgf/cm2)

1.2 (12.3) Blower LO Zone

2004 COROLLA (RM1037U)

2004 COROLLA (RM1037U)

9.8 (100, 87 in.lbf)

Cooler Refrigerant Liquid Pipe A

Cooler Refrigerant Suction Hose No. 1

9.8 (100, 87 in.lbf)

Discharge Hose Subassy

Nm (kgfcm, ftlbf) : Specified torque

2004 COROLLA (RM1037U)

HEATER CONTROL & ACCESSORY ASSY

2004 COROLLA (RM1037U)

2004 COROLLA (RM1037U)

AIR CONDITIONER UNIT ASSY

Heater to Register Duct No.1 Instrument Panel to Cowl Brace Center

Heater to Register Duct No.2

Instrument Panel Reinforcement

Instrument Panel LWR Insert LH

Instrument Panel Brace Subassy No.1

w/ Cold Area: Air Duct Rear No.4

Air Duct No.2

Air Duct No.1

Air Conditioner Unit Assy