Heater Air Conditioner

5548
HEATER & AIR CONDITIONER
AIR CONDITIONING CONTROL ASSY

550YT01
COMPONENTS
Manual A/C:
Air Conditioning Control Assy
Heater Control Housing
Air Conditioning Panel Subassy

Cooler Wire No.1
Air Conditioning Control Bulb
Heater Control Housing Subassy
Heater Control Lens Assy
Heater Control Knob
Heater Control Knob No.2
Heater Control Knob No.3
I35273
AVENSIS REPAIR MANUAL (RM1018E)
5549
Auto A/C:
Air Conditioning Control Assy
Cooler Wire No.1
Air Conditioning Panel Subassy
Control Knob Subassy
I35274
5550

550YU01
OVERHAUL
HINT:
COMPONENTS: See page 5548
1.
REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (See page 7111)
2.
REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (See page 7111)
3.
REMOVE CONSOLE PANEL SUBASSY UPPER (See page 7111)
4.
REMOVE RADIO RECEIVER ASSEMBLY W/BRACKET (See page 675)
5.
REMOVE RADIO BRACKET NO.1 (See page 675)
6.
REMOVE RADIO BRACKET NO.2 (See page 675)
7.
(a)
REMOVE AIR CONDITIONING CONTROL ASSY

Remove the air conditioning control assy as shown in the
illustration.
8.
(a)
(b)
REMOVE AIR CONDITIONING PANEL SUBASSY

Remove the 4 screws.
Manual A/C:
Release the 6 claw fittings and disconnect the air conditioning panel subassy.
(c)
Auto A/C:
Release the 4 claw fittings and disconnect the air conditioning panel subassy.
I37428
6 Claws
4 Claws
I35282
I35286
5551
(d)
Manual A/C:
Disconnect the cooler wire No.1 as shown in the illustration.
I35283
Auto A/C:
I35287
9.
10.
11.
12.
REMOVE
REMOVE
REMOVE
REMOVE
HEATER CONTROL KNOB NO.3 (MANUAL AIR CONDITIONING)

CONTROL KNOB SUBASSY (AUTO AIR CONDITIONING)
HEATER CONTROL KNOB (MANUAL AIR CONDITIONING)
HEATER CONTROL KNOB NO.2 (MANUAL AIR CONDITIONING)
13.
(a)
REMOVE HEATER CONTROL HOUSING (MANUAL

AIR CONDITIONING)
Release the 4 claw fittings and remove the 4 screws and
the heater control housing.
I35284
14.
15.
16.
REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)

17.
(a)
I35285
REMOVE AIR CONDITIONING CONTROL BULB

(MANUAL AIR CONDITIONING)
Remove the 4 air conditioning control bulbs.
5552
18.
REMOVE HEATER CONTROL HOUSING SUBASSY (MANUAL AIR CONDITIONING)
Manual A/C:
19.
(a)
REMOVE HEATER CONTROL HOUSING

Remove the 4 screws and the heater control housing.
20.
(a)
REMOVE COOLER WIRE NO.1

Remove the cooler wire No.1 as shown in the illustration.
Auto A/C:

I35833
Manual A/C:
Auto A/C:

I35834
5553
AIR CONDITIONING RADIATOR ASSY

550YV01
COMPONENTS
Defroster Nozzle Assy
Heater To Register Duct No.1
Blower Assy
9.8 (100, 87 in.lbf)
9.8 (100, 87 in.lbf)
Air Conditioning Radiator Assy
9.8 (100, 87 in.lbf)
Instrument Panel Brace Subassy No.1
Air Duct Rear No.4

Air Duct Rear No.3
Nm (kgfcm, ftlbf)
: Specified torque
I35275
5554
Cooler Thermistor No.1
Auto A/C:
Airmix No.2 Damper
Servo Subassy
Mode Damper Servo
Subassy
Air Duct No.2
Cooler Air Hose

Heater Piping Cover
RHD Auto A/C:
Air Duct No.1
Airmix Damper Servo Subassy

3.5 (35, 30 in.lbf)
w/o Hot gas heater:

Cooler Expansion Valve
Air Conditioning
Wire No.1
Cooler Evaporator
Subassy No.1
Cooler Unit Drain Hose No.1

Oring
Oring
w/o Hot gas heater:

Air Conditioning
Tube Assy
w/ Hot gas heater:
Heater Radiator Unit Subassy
Nm (kgfcm, ftlbf)
Air Conditioning
Tube Assy
: Specified torque
Nonreusable part
Compressor oil NDOIL 8 or equivalent
I35276
551
AIR CONDITIONING SYSTEM

5507E03
PRECAUTION
1.
2.
DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

AREA OR NEAR AN OPEN FLAME
ALWAYS WEAR EYE PROTECTION
AC2810
3.
AC2811
Wrong
LO
HI
6.
Okay
LO
HI
N11084
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 cold water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a hospital or see a physician 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
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 may 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
Open and close the only low pressure valve. If the high pressure
valves are opened, refrigerant flows in the reverse direction and
cause the charging cylinder to rupture.
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.
552
9.
DO NOT OPERATE ENGINE AND COMPRESSOR

WITH NO REFRIGERANT IS FILLED
CAUTION:
This may damage the inside of the compressor because
the compressor parts always moves regardless of whether
the A/C system is turned on or off.
553

550ZC01
ONVEHICLE INSPECTION
1.
(a)
(b)
(c)
2
(d)
1
(+)
(V)
4.9
4.8
()
INSPECT AIR CONDITIONER PRESSURE SENSOR

Disconnect the pressure SW connector.
Install the manifold gauge set (See page 5538).
Connect the positive (+) lead from the three 1.5 V dry cell
batteries to terminal 3 and negative () lead to terminal 1.
Check the voltage between terminals 2 and 1 of pressure
sensor.
Standard:
The voltage varies with on the refrigerant pressure as
shown in the chart.
Dry Cell Battery
1.0
0.5
0.1
0 0.39
3.19
MPa
I35425
2.
(a)
INSPECT AIR CONDITIONING CONTROL ASSY

Disconnect the connector from air conditioning control assy and inspect the connector on wire harness
side, as shown in the table.
Wire Harness Side:

Connector B
Connector A
I35437
Symbols
(Terminal No.)
Condition
Specified condition
IG (B1) GND (B40)
Ignition switch: LOCK ON
0 10 to 14 V
+B (B2) GND (B40)
Always
10 to 14 V
GND (B40) Body ground
Always
Continuity
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.
554
(b)
Connect the connector to air conditioning control assy and inspect wire harness side connector from
the back side, as shown in the table.
From Back Side:

Connector B
Connector A
I36091
Symbols
(Terminal No.)
Condition
Specified condition
HI (A4) GND (A1)
Ignition switch ON
Turn blower dial: OFF " HI
No continuity " Continuity
M2 (A5) GND (A1)
Ignition switch: ON
Turn blower dial: OFF " M2
M1 (A6) GND (A1)
Ignition switch: ON
Turn blower dial: OFF " M1
GND (A1) Body ground
Ignition switch: ON
Turn blower dial: OFF " LO
RDEFIN (B4)
GND (B40) (*1)
Ignition switch : ON
Rear DEF switch: ON
10 to 14 V
S52 (B5) GND (B40)
Ignition switch: ON
5.0 V
S53 (B6) GND (B40)
Ignition switch: ON
5.0 V
S5 (B7) GND (B40)
Ignition switch: ON
5.0 V
MPX+ (B9) GND (B40)
Communication circuit
FRS (B10) GND (B40)
Ignition switch: ON
R/F switch: RECIRCURATION " FRESH
10 to 14 " 0 V
REC (B11) GND (B40)
Ignition switch: ON
R/F switch: FRESH " RECIRCURATION
10 to 14 " 0 V
AOD (B12) GND (B40)
Ignition switch: ON
Mode control dial: DEF
10 to 14 V
AOF (B13) GND (B40)
Ignition switch: ON
Mode control dial: FACE
10 to 14 V
MGV (B14)
GND (B40) (*2)
Start engine
Hot gas heater: Operate
10 to 14 " 0 V
AMH (B15) GND (B40)
Ignition switch: ON
Temperature control dial: MAX HOT
10 to 14 V
AMC (B16) GND (B40)
Ignition switch: ON
Temperature control dial: MAX COOL
10 to 14 V
SOL+ (B17) GND (B40)
Start engine
Compressor: Operate
ILL+ (B21)
GND (B40)
HOTGASIN (B22)
GND (B40) (*2)
Ignition switch: ON
Turn light control switch: OFF " ON
Ignition switch: ON
Heater switch: ON
Pulse generation
0 " 10 to 14 V
10 to 14 V
CFAN (B23) GND (B40)
Start engine
Condenser fan: operate
RPTC1 (B28) GND (B40)
PTC heater: Operate
Above 7.5 V
MPX (B29) GND (B40)
Communication circuit
TE (B31) GND (B40)
Evaporator temperature: 0C (32F) " 15C (59F)
10 to 14 " 0 V
2.0 to 2.4 " 1.4 to 1.8 V
555
Symbols
(Terminal No.)
Condition
Specified condition
PRE (B32) GND (B40)
Start engine
Refrigerant pressure: 0 Pa (0 kgf/cm2, 0 psi) 3,138 MPa (32.0 kgf/cm2, 455 psi)
0.5 to 4.8 V
TPM (B33) GND (B40)
Ignition switch: ON
Mode control dial: DEF FACE
14V
Ignition switch: ON
Temperature control dial: MAX HOT MAX COOL
14V
TP (B34) GND (B40)

HRIN (B35) GND (B40)
Ignition switch: ON
Front blower: Operate
Below 1.0 V
SG2 (B36) Body ground
Always
Continuity
Always
Continuity
SG (B38) Body ground
Always
Continuity
Always
Continuity
GND (B40) Body ground
Always
Continuity
PBLT (B24) GND (B40)
Ignition switch: ON
Seat belt signal: OFF ON
10 to 14 Below 1.0 V
Ignition switch: ON
Parking brake switch: OFF ON
10 to 14 Below 1.0 V
PBKIG (B25) GND (B40)

ALT (B26) GND (B40)
Start engine
Pulse generation
(*1) Petrol only

(*2) Diesel (standard) only
If circuit is not as specified, try replacing the air conditioning control assy with a new one. If circuit is not as
specified, inspect the circuits connected to other parts.
556

550RQ02
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom
Suspect Area
See page
Whole functions of the A/C system does not operate.
4. ECUB fuse
5. A/C amplifier assy
6. Wire harness or connector
553
Air Flow Control : No blower operation
1.
2.
3.
4.
5.
Blower resistor
Heater relay
Blower w/ fan motor subassy
A/C amplifier assy
Wire harness or connector
557
557
557
553
Air Flow Control : No blower control
1.
2.
3.
4.
Blower w/fan motor subassy

Blower resistor
A/C amplifier assy
557
557
553
Air Flow Control : Insufficient air out
1.
2.
3.
4.
Blower w/fan motor subassy

Blower resistor
A/C amplifier assy
557
557
553
Temperature Control : No cool air comes out
1.
2.
3.
4.
5.
6.
7.
8.
9.
Volume of refrigerant
Drive belt tension
Refrigerant pressure
Cooler compressor assy
Pressure sensor
Condenser fan
Air mix damper servo subassy
A/C amplifier assy
5524
5546
5524
557
553
557
553
Temperature Control : No warm air comes out
1.
2.
3.
4.
5.
6.
Engine coolant volume

Cooler thermistor No.1
Air mix damper servo subassy
A/C amplifier assy
Heater radiator unit subassy
557
553
557
553
Temperature Control : Output air is warmer or cooler than the set

temperature or response is slow.

2. Air mix damper servo subassy
3. Air mix level
553
557
Temperature Control : No temperature control

2. Air mix damper servo subassy
3. Air mix level
553
557
No air inlet control
1. Recirculation damper servo subassy

557
553
No air outlet control

2. Mode damper servo subassy
3. Mode lever
553
557
Engine idle up does not occur, or is continuous
1.
2.
3.
4.
Idle up switch
Cooler compressor assy
A/C amplifier assy
557
557
553
Brightness does not changes when rheostat volume or light control switch it turned.
1. Illumination light system

553
557

550ZD01
INSPECTION
1.
INSPECT
COMPRESSOR
(MANUAL
AIR
CONDITIONING)
(a) Measure the resistance between terminals 1 and 2.
Resistance: 10 to 11 at 25C (77F)
If the resistance is not as specified, replace the compressor
assy.
E61224
2.
(a)
E32877
INSPECT BLOWER RESISTOR (MANUAL AIR

CONDITIONING)
Measure resistance between terminals, as shown in the
table.
Tester connection
Specified condition
12
1.404 to 1.716
13
0.504 to 0.616
14
3.024 to 3.696
If resistance is not as specified, replace the blower resistor.
558
LHD Models:
3.
REC
FRS
I36092
I36094
RHD Models:
REC
FRS
I36093
I36094
INSPECT RECIRCULATION DAMPER SERVO

SUBASSY (MANUAL AIR CONDITIONING)
(a) Inspect servomotor operation.
(1) Connect the positive (+) lead from the battery to terminal 3 and negative () lead to terminal 2, then
check that the arm turns to FRS side smoothly.
check that the arm turns to REC side smoothly.
If operations are not as specified, replace the mode damper
servomotor.
559
4.
I30157
To MAX HOT
To MAX COOL
I30162
INSPECT AIRMIX DAMPER SERVO SUBASSY

check that the arm turns to MAX COOL side
smoothly.
check that the arm turns to MAX HOT side
smoothly.
If operations are not as specified, replace the servomotor.
5510
5.
I30157
To DEF
To FACE
I30116
INSPECT MODE DAMPER SERVO SUBASSY

check that the arm turns to DEF side smoothly.
check that the arm turns to FACE side smoothly.
If operations are not as specified, replace the servomotor.
5511
6.
INSPECT COOLER THERMISTOR NO.1 (MANUAL AIR

CONDITIONING)
(a) Check the resistance between terminal 1 and 2 of cooler
thermistor No. 1 at each temperature, as shown in the
graph.
Standard: 1,500 at 25C (77F)
HINT:
As the temperature increases, the resistance decreases.

E50650
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.
7.
INSPECT BLOWER W/FAN MOTOR SUBASSY

(a) Connect the positive (+) lead from the battery to terminal
1 and negative () to terminal 2, then check that the motor
operation smoothly.
If operation is not as specified, replace the blower motor.
RHD
LHD
I30151
5512
8.
INSPECT HEATER
CONDITIONING)
Terminal No.
RELAY
(MANUAL
AIR
Specified condition
No continuity
35
Less than 1
(When battery voltage applied to terminals 1 and 2.)
Less than 1
E32993
34
No continuity
(When battery voltage applied to terminals 1 and 2.)
12
Constant continuity
If continuity is not as specified, replace the rear cooler relay.
5564
BLOWER ASSY
BLOWER ASSY
550YQ01
COMPONENTS
Blower Assy
9.8 (100, 87 in.lbf)
Air Duct No.2
Recirculation Damper Servo Subassy
Manual A/C:
Air Conditioning Wire No.1
Air Filter
Auto A/C:
Cooler Wiring No.1
Air Filter Case
Blower w/ fan Motor Subassy

Blower Motor Control
Manual A/C:
Blower Resistor
Nm (kgfcm, ftlbf) : Specified torque
I35277
5565
BLOWER ASSY
550YR01
OVERHAUL
HINT:
1.
REMOVE INSTRUMENT PANEL LOWER ASSY (See page 7111)
HINT:
Refer to the instructions for removal of the instrument panel lower assy.
2.
REMOVE ECM (See page 1065)
3.
REMOVE AIR DUCT NO.2 (See page 5555)
Clamp
Clamp
4.
(a)
REMOVE BLOWER ASSY

Disconnect the connector and the clamp.
(b)
RHD Auto A/C:

Disconnect the connector and the clamp.
(c)
(d)
(e)
Disconnect the connectors.

Remove the 2 nuts.
Remove the 2 bolts and the 2 screws.
(f)
Release the claw fitting and remove the blower assy.
I36810
I36811
I35314
I35315
5566
2 Claws
6.
BLOWER ASSY
5.
(a)
REMOVE AIR FILTER CASE

Release the 2 claw fittings and remove the air filter case.
7.
REMOVE RECIRCULATION DAMPER SERVO

SUBASSY
Remove the 2 screws and the recirculation damper servo
subassy.
I35316
REMOVE AIR FILTER
(a)
I35318
8.
(a)
(b)
Clamp
REMOVE AIR CONDITIONING WIRENO1 (MANUAL

AIR CONDITIONING)
Disconnect the connector.
Release the clump and remove the air conditioning wire
No.1.
I35319
9.
REMOVE COOLER WIRING NO.1 (AUTO AIR CONDITIONING)
HINT:
Disconnection of the cooler wiring No.1 is the same as the air conditioning wire No.1.
10.
(a)
I35320
REMOVE BLOWER RESISTOR (MANUAL AIR

CONDITIONING)
Remove the 2 screws and the blower resistor.
5567
11.
(a)
BLOWER ASSY
REMOVE BLOWER MOTOR CONTROL (AUTO AIR

CONDITIONING)
Remove the 2 screws and the blower motor control.
I35321
12.
(a)
REMOVE BLOWER W/FAN MOTOR SUBASSY

Remove the 3 screws and the blower w/ fun motor sub
assy.
13.
(a)
INSTALL AIR FILTER

Install the air filter as shown in the illustration.
14.
(a)
INSTALL BLOWER ASSY

Install the blower assy with the claw fitting.
(b)
Install the blower assy with the 2 bolts and the 2 screws.
Torque: 9.8 Nm (100 kgfcm, 87 in.lbf) (Bolt)
Install the 2 nuts.
Connect the connectors.
I35322
I35317
I36813
(c)
(d)
I35314
5568
Clamp
Clamp
BLOWER ASSY
(e)
RHD Auto A/C:

Connect the connector and the clamp.
(f)
Connect the connector and the clamp.
I36811
I36810
5515
COMBUSTION TYPE POWER HEATER SYSTEM

550ZG01
NOTICE:

If the glow plug breaks, the ECU detects the breakage and stops the automatic operation, so
the burner heater does not activate. (For other failures, similarly activated.)

The cause of failures (such as voltage malfunction, overheating malfunction, shortcircuit or
breakage of functional components, etc.) and repair methods are shown by connecting the DTC
tester and reading the DTC.
1.
DIAGNOSTICS FUNCTION
(a) Connect the DTC tester between the connector A (Vehicle harness) of DTC check harness and connector B (Power heater harness).
(b) Start the engine.
(c) Pressing the DTC calling button displays a 3digit number DTC.
Connector A
Connector B
DTC Display
In Normal
DTC Check Harness

In Malfunction
Past Record
Control Panel
Current Display
Heating
Symbol
Memory Clear Button

DTC Calling Button

DTC Calling Button

I12508
5516
2.
(a)
3.
(a)
4.
DESCRIPTION OF DISPLAY AND BUTTONS

AF: Current Value Malfunction (Blinking at current failure)
Diag: DTC (Example: 064 Flame sensor break)
Memory Clear button: Deletion of faulty memory (Press both buttons together for longer than 2 seconds)
> Button: Scroll up of faulty memory (The past 5 codes can be stored.)
< Button: Scroll down of faulty memory (The past 5 codes can be stored.)
FAULTY MEMORY
The ECU is able to store up to 5 pieces of faulty memory. If it is full, the new data is written over F5.
WIRING DIAGRAM
Connector A
Battery
Burner Motor
13
WR (*1)
YR (*2)
14
Glow Plug
BR
BR
12
5
6
RG
6
Power
Heater
ECU
G
2
LY
L
Y
3
4
Fuse (20 A)
RB
3
Temp. Control Sensor
Metering Pump
WB
1
Surface Sensor
Terminal L
of Alternator
RL (*1)
RY (*2)
IG
SW
Vehicle Side
8
LW
4
Flame Sensor
1
2
Connector B
*1: TMC Made

*2: TMUK Made
I35431
5517
5.
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit listed for the code in the table below
and proceed to the appropriate page.
DTC No.
Description of fault
Comment / Remedy
000
No malfunction
010
Overvoltage shutoff
011
Undervoltage shutoff
012
Overheating
Check temperature at temperature or overheating sensor >

125 _C
Check water circuit.
014
Possible overheating detected

(Hardware threshold value)
Difference of measured values at temperature sensor > 15 _C

(min. 70 _C water temperature and metering pump in operation);
Check temperature sensor and overheating sensor, replace if
necessary.
017
Overheating detected
(Hardware threshold value)
Temperature at temperature or overheating sensor > 130 _C,

emergency OFF if DTC No. 012 or 014s not applicable;
Check water circuit, temperature sensor and overheating sensor, replace if necessary.
020
Glow plug break
Check glow plug, replace if necessary.
021
Glow plug output overload
Check glow plug, replace if necessary.
030
Combustion air blower motor

EMF outside perm. range.
Blower impeller or burner motor fammed (frozen solid, dirty,

etc.)
Remedy jam, replace burner motor if necessary.
031
Combustion air blower motor break
Check the lead to combustion air motor (burner motor) for

continuity, replace if necessary.
032
Combustion air blower motor shortcircuit
Check combustion air blower motor (burner motor), replace if

necessary.
Check supply lead (chafed, etc.).
047
Metering pump shortcircuit
Check the supply lead to metering pump for shortcircuit,

check metering pump, replace if necessary.
048
Metering pump break
Check the supply lead to metering pump for continuity, remedy

break, replace metering pump if necessary.
051
Cold blow time exceeded
At start, if flame sensor above 70 _C, > 240 sec.;

Check exhaust gas combustion air supply, check flame sensor, replace if necessary.
052
Safety time exceeded
When all perm. start attempts used up;

Check the fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
054
Flame cutout, High setting
056
Flame cutout, LOW setting
060
Temperature control sensor break
Check connecting leads.

Resistance value between 2 and 10 connector B > 2 M (if
break)
061
Temperature control sensor shortcircuit

Resistance value between 2 and 10 at connector B < 2 M (If
short circuit)
064
Flame sensor break

Resistance value between 7 and 14 at connector B > 3,040
(If break)
065
Flame sensor shortcircuit

Resistance value between 7 and 14 at connector B > 780 (If
shortcircuit)
Voltage between 1 and 5 at connector A > 16 V

Voltage between 1 and 5 at connector A < 10.2 V
(Voltage values must be present > 20 seconds)
Check battery, regulator and electrical leads.
Check the fuel delivery and fuel supply.

Check exhaust gas combustion air ducts.
If combustion OK Check the flame sensor, replace if necessary.
5518
DTC No.
Description of fault

Comment / Remedy
071
Surface sensor break

Resistance value between 4 and 11 at connector B > 2 MW (If
break)
072
Surface sensor shortcircuit

Resistance value between 4 and 11 at connector B > 50 W (If
shortcircuit)
090
092
093
Control unit detective (Internal fault / Reset)

Control unit detective (ROM error)
Control unit detective (RAM error)
Control unit malfunction due to interference voltage from vehicle electrical system;
possible causes low batteries, chargers, other sources of
interference; eliminate interference voltages.
Internal faults detected in microprocessor / memory detected.
Replace control unit.
097
Internal control unit faults
Other faults which cannot lead to DTC No. 90, 92 and 93,
replace control unit.
5519

550ZH01
INSPECTION
1.
(a)
INSPECT HEATER ASSY

Inspect the water temperature sensor.
(1) Using an ohmmeter, measure the resistance between the terminals 3 and 4 of heater wire.
Resistance: Refer to the graph
If the resistance is not as specified, replace the heater wire.
I32392
(b)
Inspect the overheat sensor.

(1) Using an ohmmeter, measure the resistance between the terminals 5 and 6 of heater wire.
I32393
(c)
Inspect the glow plug.

(1) Using an ohmmeter, check the continuity by measure the resistance between terminals 9 and 12 of
heater wire.
Standard resistance: about 0.5 (20C, reference
value)
If the resistance is over 1 , replace the heater wire.
Ohmmeter
9
12
I12755
5520
(d)
Inspect the flame sensor.

(1) Using an ohmmeter, measure the resistance between terminals 1 and 2 of heater wire.
1
2
I32394
2.
(a)
Wire harness side:
INSPECT HETER SWITCH ASSY

Disconnect the connector from the power heater switch
and inspect the connector on the wire harness side, as
shown in the chart.
I32395
Tester connection
Condition
Specified condition
2 Ground
Constant
Continuity
4 Ground
Constant
Continuity
3 Ground
Turn ignition switch ON
Battery voltage
3 Ground
Turn ignition switch OFF
No voltage
1 Ground
Turn light control switch TAIL or HEAD
Battery voltage
1 Ground
Turn light control switch OFF
No voltage
S
S
If the circuit is as specified, replace the power heater switch.

If the circuit is not as specified, inspect the circuits
connected to other parts.
5521
(b)
From back side:
Connect the connector to the power heater switch and inspect the connector from the back side, as shown in the
chart.
I32396
Tester connection
Condition
Specified condition
6 Ground
Turn the ignition switch ON and power heater

switch ON
Battery voltage
6 Ground
Turn the ignition switch ON and power heater

switch OFF
No voltage
If the circuit is not as specified, replace the power

heater switch.
5513
ELECTRICAL TYPE POWER HEATER SYSTEM

550ZE01

Symptom
PTC heater does not operate, when perform in these conditions:

Engine coolant temp.: 70C (158F) or below
Engine speed: 650 rpm or above
Temperature control selector: MAX. HOT
Ambient temperature: Below 10C (50F)
Suspect Area
1.
2.
3.
4.
5.
6.
7.
HTR1 Fuse
HTR2 Fuse
HTR1 relay
HTR2 relay
PTC heater
ECM
Wire harness
See page
5514
5514

550ZF01
INSPECTION
1.
(a)
INSPECT HEATER ASSY

Check continuity.
(1) Using an ohmmeter, check for continuity between
each terminal of connector and earth wire.
If no continuity, replace the heater radiator.
I32391
5513

550ZE01

Symptom
PTC heater does not operate, when perform in these conditions:

Engine coolant temp.: 70C (158F) or below
Engine speed: 650 rpm or above
Temperature control selector: MAX. HOT
Ambient temperature: Below 10C (50F)
Suspect Area
1.
2.
3.
4.
5.
6.
7.
HTR1 Fuse
HTR2 Fuse
HTR1 relay
HTR2 relay
PTC heater
ECM
Wire harness
See page
5514
5514

550ZF01
INSPECTION
1.
(a)
INSPECT HEATER ASSY

Check continuity.
(1) Using an ohmmeter, check for continuity between
each terminal of connector and earth wire.
If no continuity, replace the heater radiator.
I32391
55100
HEATER ASSY
HEATER ASSY
550YS01
REPLACEMENT
1.
2.
REMOVE AIR CLEANER ASSY (See page 1182)

REMOVE FUEL FILTER ASSY (See page 1182)
Claw
3.
(a)
REMOVE AIR DUCT NO.3

Release the claw fitting and remove the bolt and the engine room relay No.2 block.
(b)
Remove the clip and the air duct No.3.
4.
(a)
DISCONNECT HEATER INLET WATER HOSE

Using pliers, grip the claws of the clip and slide the clip to
disconnect the heater inlet water hose.
I35345
I35346
HINT:
Prepare a support plate and waste to catch the leaked coolant.
I35347
5.
(a)
DISCONNECT HEATER WATER INLET HOSE A

disconnect the heater inlet water hose A.
HINT:
Prepare a support plate and waste to catch the leaked coolant.
I35348
55101
6.
(a)
HEATER ASSY
REMOVE HEATER ASSY

disconnect the heater fuel hose.
HINT:
Prepare a support plate and waste to catch the leaked fuel.
(b) Disconnect the connector.
I35349
(c)
Remove the 2 bolts and the heater assy.
7.
(a)
INSTALL HEATER ASSY

Install the heater assy with the 2 bolts.
Torque: 7.5 Nm (76 kgfcm, 66 in.lbf)
Connect the connector.
I35350
(b)
I35350
(c) Install the heater fuel hose.

HINT:
Prepare a support plate and waste to catch the leaked fuel.
I35349
8.
9.
10.
11.
12.
INSTALL FUEL FILTER ASSY (See page 1182)

INSTALL AIR CLEANER ASSY (See page 1182)
ADD ENGINE COOLANT (See page 1644)
CHECK FOR ENGINE COOLANT LEAKS (See page 1637)
CHECK FUEL LEAK (See page 1156)
5522
HOT GAS TYPE POWER HEATER SYSTEM

550ZI01
1.
(a)
INSPECT AIR CONDITIONING CONTROL ASSY

Disconnect the connector from air conditioning control assy and inspect the connector on wire harness
side, as shown in the table.
Wire harness side:
Connector A
Connector B
I35437
Symbols (Terminal No.)

SOL+ (B17)
GND (B40)
Wiring Color
Condition
STD Voltage (V)
R WB
Start engine
Compressor: Operate
Pulse generation
MGV (B14)
GND (B40) (*1)
RY WB
Start engine
Compressor: Operate
Pulse generation
HOT GAS IN (B22)

GND (B40) (*1)
RY WB
IG SW: ON
Hot Gas SW: ON
Battery 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.
From back side:
Connector A
Connector B
I36091
Symbols (Terminal No.)
Condition
Specified condition
HI (A4) GND (A1)
Ignition switch ON
Turn blower dial: OFF HI
No continuity Continuity
M2 (A5) GND (A1)
Ignition switch ON
Turn blower dial: OFF M2
M1 (A6) GND (A1)
Ignition switch ON
Turn blower dial: OFF M1
GND (A1) Body ground
Ignition switch ON
Turn blower dial: OFF LO
5523

550ZJ01
INSPECTION
1.
(a)
INSPECT W/RECEIVER CONDENSER ASSY

Apply voltage between terminals and check that the refrigerant passages switch.
2.
(a)
INSPECT HETER SWITCH ASSY

Check that the continuity to the follwing terminals.
Standard:
I36136
IN
IG
I32396
Heater switch condition
Connecting terminals
Standard value
ON
IG IN
Continuity
OFF
IG IN
No continuity
ON
IG E
Continuity
OFF
IG E
No continuity
5524
REFRIGERANT
REFRIGERANT
550Z701
1.
RHD AZ Engine series:

INSPECT REFRIGERANT VOLUME
Observe the sight glass on the cooler refrigerant liquid
pipe A.
Test conditions:

All doors are fully open.

Temperature control dial is at MAX. COOL.

Engine is running at 1,500 rpm.

Blower speed control switch is at HI.

A/C switch is ON.
Sight Glass
(a)
I35292
Item
Symptom
Amount of refrigerant
Corrective Actions
Bubbles exist
Insufficient*
(1) Check for gas leakage and repair if necessary

(2) Add refrigerant until bubbles disappear
No bubbles exist
Empty, insufficient or excessive
Refer to 3 and 4
No temperature difference between compressor inlet and outlet
Empty or nearly empty

(2) Add refrigerant until bubbles disappear
Considerable temperature difference between compressor inlet and outlet
Proper or excessive
Refer to 5 and 6
Immediately after air conditioning is turned

off, refrigerant remains clear
Excessive
(1) Discharge refrigerant

(2) Vacuum and supply proper amount of
new refrigerant
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.
5525
2.
(a)
REFRIGERANT
w/o Hot gas heater:

INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
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.


A/C switch is ON.

Engine is running at 1,500 rpm.

Air inlet mode selector switch is at RECIRE.



Temperature at the air inlet is 30 35 C (86
95 F).
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)
1.2 (12.3)
0.22 (2.25)
0.2 (2.1)
Blower LO Zone
1.25 (12.8)
0.14 (1.5)
0.5 (5.0)
1.32 (13.5)
1.0 (10.0)
1.5 (15.0)
2.0 (20.0)
Pressure on HI
pressure side
MPa (kgf/cm2)
I30081
5526
REFRIGERANT
(1) When the refrigerant volume is proper:

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)
When there is moisture in the refrigeration system:
Condition : Air conditioning system periodically repeats proper and improper function.
I22117
Symptom
Probable cause
During operation, pressure on low

pressure side cycles between normal 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
Diagnosis
Drier is overly saturated
freezes at expansion valve orifice
and blocks circulation of refrigerant
Remedy
(1) Replace cooler drier
(2) Remove moisture in cycle by
repeatedly vacuuming
(3) Supply proper amount of new
refrigerant
5527
(3)
REFRIGERANT
When cooling is insufficient:
Condition: Air conditioning system does not function effectively.
I22118
Symptom
Pressure is low on both low and

high pressure sides
RHD AZ engine series:
Bubbles are seen through sight
glass continuously
Cooling performance is insufficient
Probable cause
Diagnosis
Gas leakage in refrigeration system
(4)
Insufficient refrigerant
Refrigerant leakage
Corrective Actions
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leakage.
When the circulation of the refrigerant is poor:
Condition: Air conditioning system does not function effectively.
I22119
Symptom
high pressure sides
Frost exists on piping from condenser to A/C unit
Probable cause
Refrigerant flow is obstructed by

dirt in condenser
Diagnosis
Condenser is clogged
Corrective Action
Replace condenser
5528
(5)
REFRIGERANT
When the refrigerant does not circulate:
Condition: Air conditioning system does not function. (Sometimes it may function)
I22120
Symptom
Vacuum is indicated on low pressure side, and extreamly low pressure is indicated on high pressure
side
Frost or dew is seen on piping on
both sides of condenser or expansion valve
Probable cause
Diagnosis

moisture or dirt in refrigeration system
Refrigerant does not circulate
gas leak from expansion valve
(6)
Corrective Actions
(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 expansion valve, replace expansion
valve
When the refrigerant is overcharged or cooling of

condenser is insufficient:
Condition : Air conditioning system does not function effectively.
I22121
Symptom
Pressure is extreamly high on
both low and high pressure sides
No air bubbles are seen through
sight glass even when engine rpm
lowers
Probable cause
Excessive refrigerant
Cooling performance of condenser is insufficient
Diagnosis
Remedy
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check the amount of refrigerant and supply proper amount of
refrigerant
5529
(7)
REFRIGERANT
When there is air in the refrigeration system:
Condition: Air conditioning system does not function.
NOTE : These gauge indications occur when the refrigeration system opens and the refrigerant is charged without
vacuuming.
I22122
Symptom
both low and the high pressure
sides
The low pressure piping is too
hot to touch
Bubbles can be seen through sight
glass
Probable cause
Diagnosis
There is air in refrigeration system

Vacuuming is insufficient
Air in refrigeration system
(8)
Corrective Actions
(1) Check it compressor oil is dirty

or insufficient
(2) Vacuum and supply new refrigerant
When the expansion valve malfunctions:
I22123
Symptom
Frost or dew is on piping on low
pressure side
Probable cause
Trouble with expansion valve
Diagnosis
Excessive refrigerant in low
pressure piping
Expansion valve opened too
wide
Corrective Actions
Replace expansion valve
5530
(9)
REFRIGERANT
When the compressor is defective:
Condition : Air conditioning system does not function.
I22124
Symptom
Pressure is extreamly low on
high pressure side
Probable cause
Internal leak from compressor
Diagnosis
Compression failure
Leakage from damaged valve or
broken sliding parts
Corrective Actions
Repair or replace compressor
5531
3.
(a)
(b)
REFRIGERANT
w/ Hot gas heater:

INSPECT REFRIGERANT VOLUME
manifold gauge set. Read the the manifold gauge pressure when these conditions are established.
Test conditions:
S
Engine is at idle.
S
S
S
S
S
Hood is fully open.
S
Air inlet mode selector damper is at RECIRE.
S
Air outlet damper is at FACE.
S
Outside temperature is 15 35 C (59 95
F).
Check refrigerant volume according to the graph below.
Range
Amount of refrigerant
Corrective actions
Except range below
Insufficient or excessive
Supply refrigerant until low

pressure become within
the standard 50 g
(1.76 oz.), or remove
refrigerant and then supply proper amount of refrigerant
Standard 50 g
(1.76 oz.)
Proper

MPa (kgf/cm2)
+ 50 g (+ 1.76 oz.)
0.4 (4.0)
0 g (0 oz.)
(Standard)
0.3 (3.0)
50 g ( 1.76 oz.)
0.2 (2.0)
0.1 (1.0)
0
15 (59)
20 (68)
25 (77)
30 (86)
35 (95)
Outside temperature
_C (_F)
I37057
5532
4.
(a)
REFRIGERANT
w/ Hot gas heater:

INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
manifold gauge set. Read the manifold gauge pressure
when the following conditions are fullfilled.
Test conditions:



A/C switch is ON.

Engine is at idle.

Air inlet mode selector damper is at RECIRE.



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)

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)
1.2 (12.3)
0.22 (2.25)
0.2 (2.1)
Blower LO Zone
1.25 (12.8)
0.14 (1.5)
0.5 (5.0)
1.32 (13.5)
1.0 (10.0)
1.5 (15.0)
2.0 (20.0)
Pressure on HI
pressure side
MPa (kgf/cm2)
I30081
5533
REFRIGERANT
(1) When the refrigerant volume is proper:

Gauge reading:
Low pressure side:
0.28 0.4 MPa (2.8 4.0 kgf/cm2)
High pressure side:
1.3 1.6 MPa (13 16 kgf/cm2)
E65563
(2)
When there is moisture in the refrigeration system:
Condition : Air conditioning system periodically repeats proper and improper function.
I22117
Symptom
Probable cause
During operation, pressure on low

pressure side cycles between normal and vacuum

freezes at refrigerant filter orifice,
causing a temporary stop of cycle.
However, when it melts, normal
state is restored
Diagnosis
Drier is overly saturated
freezes at refrigerant filter orifice
and blocks circulation of refrigerant
Remedy
(1) Replace cooler drier
(2) Remove moisture in cycle by
repeatedly vacuuming
refrigerant
5534
(3)
REFRIGERANT
When cooling is insufficient:
I22118
Symptom

high pressure sides
Cooling performance is insufficient
Probable cause
Diagnosis
Gas leakage in refrigeration system
(4)
Insufficient refrigerant
Refrigerant leakage
Corrective Actions
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leakage.
When the circulation of the refrigerant is poor:
I22119
Symptom
high pressure sides
Frost exists on piping from condenser to unit
Probable cause

dirt in condenser
Diagnosis
Condenser is clogged
Corrective Action
Replace condenser
5535
(5)
REFRIGERANT
When the refrigerant does not circulate:
Condition : Air conditioning system does not function. (Sometimes it may function)
I22120
Symptom
Vacuum is indicated on low pressure side, and extreamly low pressure is indicated on high pressure
side
Frost or dew is seen on piping on
both sides of condenser or refrigerant filter
Probable cause
Diagnosis

moisture or dirt in refrigeration sysRefrigerant does not circulate
tem
Refrigerant filter is clogged
(6)
Corrective Actions
(1) Check the refrigerant filter
(2) Clean out dirt on refrigerant filter by blowing air
(3) Replace condenser
(4) Vacuum air and supply proper
amount of new refrigerant
(5) If refrigerant filter is damaged,
replace it
When the refrigerant is overcharged or cooling of

condenser is insufficient:
I22121
Symptom

Probable cause
Diagnosis
Magnet valve assy is defective
Remedy
(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 after supplying refrigerant, replace
the magnet valve assy
5536
(7)
REFRIGERANT
When there is air in the refrigeration system:
NOTE : These gauge indications occur when the refrigeration system opens and the refrigerant is charged without
vacuuming.
I22122
Symptom
Probable cause
Diagnosis
There is air in refrigeration system
Vacuuming is insufficient
Pressure is extreamly high on both

Air in refrigeration system
low and the high pressure sides
(8)
Corrective Actions
(1) Check if compressor oil is dirty
or insufficient
(2) Vacuum air and supply new refrigerant
When the refrigerant filter is defective:
I22123
Symptom
low pressure side
high pressure side
Probable cause
Trouble with refrigerant filter
Diagnosis
Corrective Actions
Replace refrigerant filter
5537
(9)
REFRIGERANT
When the compressor is defective:
I22124
Symptom
low pressure side
Pressure is extreamly low on
high pressure side
Probable cause
Diagnosis
Compression failure
Leakage from damaged valve or
broken sliding parts
Internal leak from compressor
Corrective Actions
Replace or replace compressor
(10) When the magnet valve assy is defective:
I22123
Symptom
low pressure side
Probable cause
Internal leak from magnet valve
assy
Diagnosis
Magnet valve assy failure
Corrective Actions
Replace magnet valve assy
5538
REFRIGERANT
550Z801
REPLACEMENT
1.
(a)
(b)
(c)
(d)
2.
(a)
(b)
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

Turn the A/C switch ON.
Operate the cooler compressor at the engine rpm of approx. 1,000 for 5 to 6 minuites to circulate the
refrigerant and collect the compressor oil remaining in each component into the cooler compressor as
much as possible.
Shut off the engine.
Let the refrigerant gas out.
SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
CHARGE REFRIGERANT
Using a vacuum pump, perform vacuuming.
Charge refrigerant, HFC134a (R134a).
Standard: 440 30 g (15.51 1.06 oz.)
SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080)
RHD AZ Engine series:

Amount to be charged
Mean
value
in proper
range
30 g (1.06 oz.)
Hight
Pressure
Over charged
Refrigerant Amount
Subcool system

3.
4.
(a)
I37091
WARM UP ENGINE
INSPECT LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of the refrigerant.
NOTICE:
1CDFTV Hot gas heater:
Since the system uses a refrigerant filter (fixed valve), sound of the refrigerant circulation (hissing
sound) can be heard for approx. 30 seconds after turning the A/C off. This is merely a sound of balancing the low pressure with the high pressure, not a sound of abnormality.
5539
REFRIGERANT LINE
REFRIGERANT LINE
550YO01
COMPONENTS
LHD:
3ZZFE:
1ZZFE:
Cooler Refrigerant Suction Hose No.1
9.8 (100, 87 in.lbf)
Liquid Tube Subassy A
9.8 (100, 87 in.lbf)

5.4 (55, 47 in.lbf)
9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)
Cooler Refrigerant Discharge Hose No.1
Nm (kgfcm, ftlbf)
: Specified torque
I34975
5540
REFRIGERANT LINE
RHD:
3ZZFE:
1ZZFE:
9.8 (100, 87 in.lbf)
9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)
5.4 (55, 47 in.lbf)
Nm (kgfcm, ftlbf)
: Specified torque
I34976
5541
REFRIGERANT LINE
LHD:
1AZFSE:
1AZFE:
9.8 (100, 87 in.lbf)
9.8 (100, 87 in.lbf)

5.4 (55, 47 in.lbf)

9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)
Nm (kgfcm, ftlbf)
: Specified torque
I34977
5542
REFRIGERANT LINE
RHD:
1AZFSE:
1AZFE:
9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)
5.4 (55, 47 in.lbf)
Nm (kgfcm, ftlbf)
: Specified torque
I34978
5543
REFRIGERANT LINE
LHD:
1CDFTV:
w/o Hot Gas Heater:
9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)
9.8 (100, 87 in.lbf)
9.8 (100, 87 in.lbf)

5.4 (55, 47 in.lbf)
Suction Servic Valve
Nm (kgfcm, ftlbf)
: Specified torque
I34979
5544
REFRIGERANT LINE
LHD:
1CDFTV:
w/ Hot Gas Heater:
9.8 (100, 87 in.lbf)
9.8 (100, 87 in.lbf)

5.4 (55, 47 in.lbf)

9.8 (100, 87 in.lbf)

9.8 (100, 87 in.lbf)
Suction Servic Valve

Discharge Tube Subassy
9.8 (100, 87 in.lbf)

5.4 (55, 47 in.lbf)
Nm (kgfcm, ftlbf)
: Specified torque
I34980
5545
REFRIGERANT LINE
RHD:
1CDFTV:
w/ Hot Gas Heater:
Liquid Tube Subassy B
5.4 (55, 47 in.lbf)
9.8 (100, 87 in.lbf)
9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)

9.8 (100, 87 in.lbf)
5.4 (55, 47 in.lbf)

13 (132, 9.5)
9.8 (100, 87 in.lbf)
Nm (kgfcm, ftlbf)
: Specified torque
I34981
5546
V (COOLER COMPRESSOR TO CRANKSHAFT

PULLEY) BELT NO.1
V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY)

BELT NO.1
550YP01
REPLACEMENT
1.
2.
3.
REMOVE RADIATOR SUPPORT OPENING COVER

REMOVE ENGINE ROOM COVER SIDE
REMOVE ENGINE UNDER COVER RH
4.
Bolt B
(a)
(b)
REMOVE V (COOLER COMPRESSOR TO

CRANKSHAFT PULLEY) BELT NO.1
Loosen the nut A.
Loosen the bolt B and remove the V (cooler compressor
to crankshaft pulley) belt No. 1.
Nut A
I31981
5.
(a)
INSTALL V (COOLER COMPRESSOR TO

Temporarily install a new V (cooler compressor to crankshaft pulley) belt No. 1 as shown in the illustration.
I31981
6.
Bolt B
Measuring
Position
(a)
(b)
Nut A
ADJUST V (COOLER COMPRESSOR

Tighten the nut A.
Torque: 2.5 Nm (25 kgfcm, 22 ftlbf)
Apply drive belt tension by turning bolt B.
Belt deflection:
New belt: 11 13 mm (0.43 0.51 in.)
Used belt: 13.5 16.5 mm (0.53 0.64 in.)
TO
I31981
HINT:

CORRECT
WRONG
WRONG

F11928
The new belt refers to a belt which is used for less than
5 minutes on the running engine.
The used belt refers to a belt which is used for 5 minutes,
or more on the running engine.
After installing the drive belt, check that the belt fits properly in the ribbed grooves.
Check that the drive belt does not slip off the groove at the
end of the pulley by hand.
7.
(a)
Nut A
I31981
V (COOLER COMPRESSOR TO CRANKSHAFT

PULLEY) BELT NO.1
5547
FULLY TIGHTEN V (COOLER COMPRESSOR TO

Tighten the nut A.
Torque: 39 Nm (390 kgfcm, 29 ftlbf)
5581
W/PULLEY COMPRESSOR ASSY (1AZFE)

550Z301
1.
(a)
INSPECT W/PULLEY COMPRESSOR ASSY

Check the operation.
(1) Start the engine.
(2) Inspect the weight hub.
Standard: The weight hub rotates along with the pulley
Pulley
Weight Hub
Weight Hub
I37058
5582

550Z401
REPLACEMENT
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 5538)

SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
I35326
DISCONNECT COOLER REFRIGERANT SUCTION

HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant
suction hose No.1 from the w/pulley compressor assy.
(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 matters from entering.
3.
I35327
4.
5.
6.
7.
DISCONNECT COOLER REFRIGERANT DISCHARGE

HOSE NO.1
discharge hose No.1 from the w/pulley compressor assy.
(b) Remove the Oring from the cooler refrigerant discharge
hose No.1.
NOTICE:
REMOVE RADIATOR SUPPORT OPENING COVER (See page 14105)

REMOVE ENGINE ROOM COVER SIDE (See page 14105)
REMOVE ENGINE UNDER COVER RH (See page 14105)
REMOVE FAN AND GENERATOR V BELT (See page 14105)
SST 0924963010
8.
REMOVE W/PULLEY COMPRESSOR ASSY
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
I35328
9.
(a)
INSPECT COMPRESSOR OIL

When replacing the w/pulley compressor assy with a new one, after gradually removing the refrigerant
gas from the service valve, drain the following amount of oil from the new w/pulley compressor assy
before installation.
Standard:
(Oil capacity inside new w/pulley compressor assy: 90 + 15 cc (3.0 + 0.5 fl. oz.) ) (Remaining
oil amount in the removed w/pulley compressor assy) = (Oil amount to be removed when replacing)
5583
NOTICE:

When checking the compressor oil level, observe the precautions on the cooler removal/installation.

Since compressor oil remains in the pipes of the vehicle, if a new w/pulley compressor assy
is installed without removing some oil inside, the oil amount becomes excessive, preventing
heat exchange in the refrigerant cycle and causing refrigerant failure.

If the remaining oil in the removed w/pulley compressor assy is too small in volume, check for
oil leakage.

Be sure to use NDOIL 8 for compressor oil.
10.
(a)
INSTALL W/PULLEY COMPRESSOR ASSY

Install the w/pulley compressor assy with the 4 bolts.
NOTICE:
Tighten the bolts in the order shown in the illustration to
install the w/pulley compressor assy.
(b) Connect the connector.
(1)
(3)
(4)
(2)
11.
I35328
INSTALL FAN AND GENERATOR V BELT (See page 14105)

SST 0924963010
12.
(a)
(b)
(c)
I35327
(d)
Install the cooler refrigerant discharge hose No.1 on the

w/pulley compressor assy with the bolt.
13.
INSTALL COOLER REFRIGERANT SUCTION HOSE

NO.1
Remove the attached vinyl tape from the hose.
Sufficiently apply compressor oil to a new Oring and the
fitting surface of the w/pulley compressor assy.
Compressor oil: NDOIL 8 or equivalent
Install the Oring on the cooler refrigerant suction hose
No.1.
(a)
(b)
(c)
INSTALL COOLER REFRIGERANT DISCHARGE

HOSE NO.1
Install the Oring on the cooler refrigerant discharge hose
No.1.
5584
(d)
Install the cooler refrigerant suction hose No.1 on the w/

pulley compressor assy with the bolt.
I35326
14.
15.
16.
CHARGE REFRIGERANT (See page 5538)

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080)
WARM UP ENGINE (See page 5538)
INSPECT LEAKAGE OF REFRIGERANT (See page 5538)
5577
W/PULLEY COMPRESSOR ASSY (1AZFSE)

550Z101
1.
(a)

Pulley
Weight Hub
Weight Hub
I37058
5578

550Z201
REPLACEMENT
1.

SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
I35326

HOSE NO.1
hose No.1.
NOTICE:
3.
I35327
4.
5.
6.
7.

HOSE NO.1
hose No.1.
NOTICE:
REMOVE RADIATOR SUPPORT OPENING COVER (See page 14185)

REMOVE ENGINE ROOM COVER SIDE (See page 14185)
REMOVE ENGINE UNDER COVER RH (See page 14185)
REMOVE FAN AND GENERATOR V BELT (See page 14185)
SST 0924963010
8.
(a) Disconnect the connector.
(b) Remove the 4 bolts and the w/pulley compressor assy.
I35328
9.
(a)

Standard:
5579
NOTICE:



oil leakage.

10.
(a)

NOTICE:
(1)
(3)
(4)
(2)
11.
I35328
INSTALL FAN AND GENERATOR V BELT (See page 14185)

SST 0924963010
12.
(a)
(b)
(c)
I35327
(d)

13.

NO.1
No.1.
(a)
(b)
(c)

HOSE NO.1
No.1.
5580
(d)

I35326
14.
15.
16.

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080)
Specified amount: 440 30 g (15.51 1.06 oz.)
5585
W/PULLEY COMPRESSOR ASSY (1CDFTV)

550Z501
1.
(a)

Weight Hub
Pulley
Weight Hub
I37059
5586

550Z601
REPLACEMENT
1.

SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
I35329

HOSE NO.1 (LHD STEERING POSITION TYPE)
suction hose No.1 from the suction servic valve.
hose No.1.
NOTICE:
3.
REMOVE SUCTION SERVIC VALVE (LHD STEERING

POSITION TYPE)
(a) Remove the 2 bolts and disconnect the suction service
valve from the w/pulley compressor assy.
(b) Remove the Oring from the suction service valve.
NOTICE:
I35330
4.
I35331

HOSE NO.1 (RHD STEERING POSITION TYPE)
hose No.1.
NOTICE:
5.
I35332
6.
7.
8.
9.

HOSE NO.1
hose No.1.
NOTICE:
REMOVE RADIATOR SUPPORT OPENING COVER

REMOVE ENGINE ROOM COVER SIDE
REMOVE ENGINE UNDER COVER RH
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 5546)
5587
10.
(a)
(b)

Remove the 4 bolts and the w/pulley compressor assy.
I35333
11.
(a)

Standard:
NOTICE:



oil leakage.

12.
(a)

NOTICE:
(1)
(4)
(3)
(2)
13.
14.
15.
I35333
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1

(See page 5546)
ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 5546)
FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
(See page 5546)
5588
16.
(a)
(b)
(c)
I35332

HOSE NO.1
No.1.
(d)

17.

NO.1 (RHD STEERING POSITION TYPE)
No.1.
(a)
(b)
(c)
(d)
18.
(a)
(b)
I35330
(c)
(d)
19.
(a)
(b)
I35331
(c)

INSTALL SUCTION SERVIC VALVE (LHD STEERING
POSITION TYPE)
Install the Oring on the suction service valve.
Install the suction servic valve on the w/pulley compressor assy with the 2 bolts.
NO.1 (LHD STEERING POSITION TYPE)
No.1.
5589
(d)
Install the cooler refrigerant suction hose No.1 on the suction servic valve with the 2 bolts.
I35329
20.
21.
22.

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080)
5573
W/PULLEY COMPRESSOR ASSY (1ZZFE)

550YZ01
1.
(a)

Weight Hub
Pulley
Weight Hub
I35991
5574

550Z001
REPLACEMENT
1.

SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
I35323

HOSE NO.1
hose No.1.
NOTICE:
3.
I35324
4.
5.
6.
7.
REMOVE
REMOVE
REMOVE
REMOVE

HOSE NO.1
hose No.1.
NOTICE:
RADIATOR SUPPORT OPENING COVER (See page 145)

ENGINE ROOM COVER SIDE (See page 145)
ENGINE UNDER COVER SUBASSY NO.1 (See page 145)
FAN AND GENERATOR V BELT (See page 145)
8.
(a)
(b)

I35325
9.
(a)

Standard:
5575
NOTICE:



oil leakage.

10.
(a)

NOTICE:
(1)
(3)
(2)
I35325
11.
(a)
(b)
(c)
I35324
(d)

12.

NO.1
No.1.
(a)
(b)
(c)

HOSE NO.1
No.1.
5576
(d)

I35323
13.
14.
15.

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080)
5569

550YX01
1.
(a)

Weight Hub
Pulley
Weight Hub
I35991
5570

550YY01
REPLACEMENT
1.

SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
I35323

HOSE NO.1
hose No.1.
NOTICE:
3.
I35324
4.
5.
6.
7.
REMOVE
REMOVE
REMOVE
REMOVE

HOSE NO.1
hose No.1.
NOTICE:
RADIATOR SUPPORT OPENING COVER (See page 145)

ENGINE ROOM COVER SIDE (See page 145)
ENGINE UNDER COVER SUBASSY NO.1 (See page 145)
FAN AND GENERATOR V BELT (See page 145)
8.
(a)
(b)

I35325
9.
(a)

Standard:
5571
NOTICE:



oil leakage.

10.
(a)

NOTICE:
(1)
(3)
(2)
I35325
11.
(a)
(b)
(c)
(d)
12.
(a)
(b)
I35324
(c)

HOSE NO.1
No.1.

NO.1
No.1.
5572
(d)

I35323
13.
14.
15.

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080)
5590
W/RECEIVER CONDENSER ASSY

550Z901
1.
(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.
5591

550ZA01
COMPONENTS
w/o Hot gas heater:
Oring
w/ receiver Condenser Assy
5.4 (55, 47 in.lbf)
Oring
5.4 (55, 47 in.lbf)
Cooler Dryer
Cap
2.9 (30, 25 in.lbf)
1AZFSE:
Nm (kgfcm, ftlbf)
: Specified torque
Nonreusable part
I35278
5592
w/ Hot gas heater:
5.4 (55, 47 in.lbf)
Oring
Oring
5.4 (55, 47 in.lbf)

5.4 (55, 47 in.lbf)
Oring
Oring
5.4 (55, 47 in.lbf)

3.4 (35, 30 in.lbf)
5.4 (55, 47 in.lbf)
Discharge Tube
Oring
Magnet Valve Assy
3.4 (35, 30 in.lbf)
Refrigerant Filter
Oring
Discharge Tube
5.4 (55, 47 in.lbf)

Nonreusable part
I35279
5593

550ZB01
OVERHAUL
HINT:
1.
SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
REMOVE FRONT BUMPER COVER (See page 763)
3.

HOSE NO.1
discharge hose No.1 from the w/ receiver condenser
assy.
hose No.1.
NOTICE:
w/o Hot gas heater:
w/ Hot gas heater:

I35836
4.
(a)
I35335
DISCONNECT LIQUID TUBE SUBASSY A

w/o Hot gas heater:
Remove the bolt and disconnect the liquid tube subassy
A from the w/ receiver condenser assy.
(b) w/o Hot gas heater:
Remove the Oring from the liquid tube subassy A.
NOTICE:
(c)
w/ LHD Hot gas heater:

Disconnect the liquid tube subassy A assy from the liquid tube subassy B.
(d) w/ LHD Hot gas heater:
NOTICE:
I35336
5594
5.
REMOVE DISCHARGE TUBE SUBASSY (W/ HOT

GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
subassy from the w/ receiver condenser assy.
(b) Remove 2 Orings from the discharge tube subassy.
NOTICE:
I35337
6.
REMOVE
LIQUID
TUBE
SUBASSY
B
(RHD(1CDFTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube subassy
B from w/ receiver condenser assy.
(b) Remove the Oring from the liquid tube subassy B.
NOTICE:
I35336
7.
(a)
REMOVE HOOD LOCK ASSY

Remove the 3 bolts and the hood lock assy.
I35339
8.
9.
REMOVE HIGH PITCHED HORN ASSY (See page 695)

REMOVE LOW PITCHED HORN ASSY (See page 694)
10.
(a)
I35340
REMOVE HOOD LOCK SUPPORT BRACE

Remove the 5 bolts and the hood lock support brace.
5595
11.
(a)
REMOVE W/RECEIVER CONDENSER ASSY

Remove the bolt and the w/ receiver condenser assy.
12.
(a)
REMOVE DISCHARGE TUBE (W/ HOT GAS HEATER)

Remove the 2 bolts and the discharge tube.
13.
REMOVE REFRIGERANT FILTER (W/ HOT GAS

HEATER)
Disconnect the discharge tube and remove the refrigerant filter.
I35341
I35342
(a)
I35343
14.
(a)
REMOVE MAGNET VALVE ASSY (W/ HOT GAS

HEATER)
Remove the 4 bolts and the magnet valve assy.
I35344
15.
(a)
(b)
14 mm
(0.55 in.)
Hexagon
Wrench
Modulator
I32993
REMOVE COOLER DRYER (W/O HOT GAS HEATER)

1AZFSE:
Remove the 2 bolts and bracket.
Using a hexagon wrench 14 mm (0.55 in.), remove the
cap from the modulator.
5596
(c)
Using needle nose pliers, remove the cooler dryer.
I32994
16.
17.
18.
REMOVE COOLER CONDENSER CUSHION NO.1

REMOVE CONDENSER BRACKET COLLAR NO.1
19.
(a)
INSTALL COOLER DRYER (W/O HOT GAS HEATER)

Using needle nose pliers, install the new cooler dryer.
(b)
Sufficiently apply compressor oil to the fitting surfaces of

the Oring.
(c)
Using a hexagon wrench 14 mm (0.55 in.), install the new

cap on the modulator.
1AZFSE:
Install the bracket with the 2 bolts.
I32994
E55408
I32475
(d)
14 mm
(0.55 in.)
Hexagon
Wrench
Modulator
I32993
5597
20.
(a)
INSTALL MAGNET VALVE ASSY (W/ HOT GAS

HEATER)
Install the magnet valve assy with the 4 bolts.
I35344
21.
(a)
INSTALL REFRIGERANT FILTER (W/ HOT GAS

HEATER)
Install the refrigerant filter to the discharge tube.
I35343
22.
(a)
INSTALL DISCHARGE TUBE (W/ HOT GAS HEATER)

Install the discharge tube with the 2 bolts.
23.
INSTALL LIQUID TUBE SUBASSY B (RHD(1CDFTV)

STEERING POSITION TYPE)
Remove the attached vinyl tape from the tube and the
connecting part of the w/ receiver condenser assy.
fitting surface of the pipe joint.
Install the Oring on the liquid tube subassy B.
(a)
I35342
(b)
(c)
(d)
24.
(a)
(b)
I35336
(c)
Install the liquid tube subassy B on the w/ receiver condenser assy with the bolt.
INSTALL DISCHARGE TUBE SUBASSY (W/ HOT
GAS HEATER)
Sufficiently apply compressor oil to a new 2 Orings and
the fitting surface of the pipe joint.
Install the Oring on the discharge tube subassy.
5598
(d)
25.
(a)
(b)
I35337
(c)
(d)
Install the discharge tube subassy on the w/ receiver

condenser assy with the bolt.
INSTALL LIQUID TUBE SUBASSY A
Install the Oring on the liquid tube subassy A.
w/o Hot gas heater:
Install the liquid tube subassy A on the w/ receiver condenser assy core with the bolt.
I35335
(e)

Install the liquid tube subassy A on the w/ receiver condenser assy with the bolt.
26.

HOSE NO.1
Sufficiently apply compressor oil to the Oring and the fitting surface of the hose joint.
No.1.
(a)
I35336
(b)
(c)
5599
(d)
w/o Hot gas heater:

w/ receiver condenser assy with the bolt.
w/ Hot gas heater:

27.
28.
29.
30.
I35837
INSTALL FRONT BUMPER COVER (See page 763)

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080), 0711748130, 0711748140
5590

550Z901
1.
(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.
5591

550ZA01
COMPONENTS
w/o Hot gas heater:
Oring
5.4 (55, 47 in.lbf)
Oring
5.4 (55, 47 in.lbf)
Cooler Dryer
Cap
2.9 (30, 25 in.lbf)
1AZFSE:
Nm (kgfcm, ftlbf)
: Specified torque
Nonreusable part
I35278
5592
w/ Hot gas heater:
5.4 (55, 47 in.lbf)
Oring
Oring
5.4 (55, 47 in.lbf)

5.4 (55, 47 in.lbf)
Oring
Oring
5.4 (55, 47 in.lbf)

3.4 (35, 30 in.lbf)
5.4 (55, 47 in.lbf)
Discharge Tube
Oring
Magnet Valve Assy
3.4 (35, 30 in.lbf)
Refrigerant Filter
Oring
Discharge Tube
5.4 (55, 47 in.lbf)

Nonreusable part
I35279
5593

550ZB01
OVERHAUL
HINT:
1.
SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070,
0711788080)
2.
REMOVE FRONT BUMPER COVER (See page 763)
3.

HOSE NO.1
discharge hose No.1 from the w/ receiver condenser
assy.
hose No.1.
NOTICE:
w/o Hot gas heater:
w/ Hot gas heater:

I35836
4.
(a)
I35335
DISCONNECT LIQUID TUBE SUBASSY A

w/o Hot gas heater:
Remove the bolt and disconnect the liquid tube subassy
A from the w/ receiver condenser assy.
(b) w/o Hot gas heater:
NOTICE:
(c)

Disconnect the liquid tube subassy A assy from the liquid tube subassy B.
(d) w/ LHD Hot gas heater:
NOTICE:
I35336
5594
5.
REMOVE DISCHARGE TUBE SUBASSY (W/ HOT

GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
subassy from the w/ receiver condenser assy.
(b) Remove 2 Orings from the discharge tube subassy.
NOTICE:
I35337
6.
REMOVE
LIQUID
TUBE
SUBASSY
B
(RHD(1CDFTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube subassy
B from w/ receiver condenser assy.
(b) Remove the Oring from the liquid tube subassy B.
NOTICE:
I35336
7.
(a)
REMOVE HOOD LOCK ASSY

Remove the 3 bolts and the hood lock assy.
I35339
8.
9.
REMOVE HIGH PITCHED HORN ASSY (See page 695)

REMOVE LOW PITCHED HORN ASSY (See page 694)
10.
(a)
I35340
REMOVE HOOD LOCK SUPPORT BRACE

Remove the 5 bolts and the hood lock support brace.
5595
11.
(a)
REMOVE W/RECEIVER CONDENSER ASSY

Remove the bolt and the w/ receiver condenser assy.
12.
(a)
REMOVE DISCHARGE TUBE (W/ HOT GAS HEATER)

Remove the 2 bolts and the discharge tube.
13.
REMOVE REFRIGERANT FILTER (W/ HOT GAS

HEATER)
Disconnect the discharge tube and remove the refrigerant filter.
I35341
I35342
(a)
I35343
14.
(a)
REMOVE MAGNET VALVE ASSY (W/ HOT GAS

HEATER)
Remove the 4 bolts and the magnet valve assy.
I35344
15.
(a)
(b)
14 mm
(0.55 in.)
Hexagon
Wrench
Modulator
I32993
REMOVE COOLER DRYER (W/O HOT GAS HEATER)

1AZFSE:
Remove the 2 bolts and bracket.
Using a hexagon wrench 14 mm (0.55 in.), remove the
cap from the modulator.
5596
(c)
Using needle nose pliers, remove the cooler dryer.
I32994
16.
17.
18.

REMOVE CONDENSER BRACKET COLLAR NO.1
19.
(a)
INSTALL COOLER DRYER (W/O HOT GAS HEATER)

Using needle nose pliers, install the new cooler dryer.
(b)
Sufficiently apply compressor oil to the fitting surfaces of

the Oring.
(c)
Using a hexagon wrench 14 mm (0.55 in.), install the new

cap on the modulator.
1AZFSE:
Install the bracket with the 2 bolts.
I32994
E55408
I32475
(d)
14 mm
(0.55 in.)
Hexagon
Wrench
Modulator
I32993
5597
20.
(a)
INSTALL MAGNET VALVE ASSY (W/ HOT GAS

HEATER)
Install the magnet valve assy with the 4 bolts.
I35344
21.
(a)
INSTALL REFRIGERANT FILTER (W/ HOT GAS

HEATER)
Install the refrigerant filter to the discharge tube.
I35343
22.
(a)
INSTALL DISCHARGE TUBE (W/ HOT GAS HEATER)

Install the discharge tube with the 2 bolts.
23.
INSTALL LIQUID TUBE SUBASSY B (RHD(1CDFTV)

STEERING POSITION TYPE)
Install the Oring on the liquid tube subassy B.
(a)
I35342
(b)
(c)
(d)
24.
(a)
(b)
I35336
(c)
Install the liquid tube subassy B on the w/ receiver condenser assy with the bolt.
INSTALL DISCHARGE TUBE SUBASSY (W/ HOT
GAS HEATER)
Sufficiently apply compressor oil to a new 2 Orings and
the fitting surface of the pipe joint.
Install the Oring on the discharge tube subassy.
5598
(d)
25.
(a)
(b)
I35337
(c)
(d)
Install the discharge tube subassy on the w/ receiver

condenser assy with the bolt.
INSTALL LIQUID TUBE SUBASSY A
Install the Oring on the liquid tube subassy A.
w/o Hot gas heater:
Install the liquid tube subassy A on the w/ receiver condenser assy core with the bolt.
I35335
(e)

Install the liquid tube subassy A on the w/ receiver condenser assy with the bolt.
26.

HOSE NO.1
Sufficiently apply compressor oil to the Oring and the fitting surface of the hose joint.
No.1.
(a)
I35336
(b)
(c)
5599
(d)
w/o Hot gas heater:

w/ receiver condenser assy with the bolt.
w/ Hot gas heater:

27.
28.
29.
30.
I35837
INSTALL FRONT BUMPER COVER (See page 763)

SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050,
0711788060, 0711788070, 0711788080), 0711748130, 0711748140

Heater Air Conditioner

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Heater Air Conditioner

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5548

HEATER & AIR CONDITIONER

AIR CONDITIONING CONTROL ASSY

AIR CONDITIONING CONTROL ASSY

Heater Control Housing

Air Conditioning Panel Subassy

Air Conditioning Control Bulb

Heater Control Housing Subassy

Heater Control Lens Assy

Heater Control Housing

Heater Control Knob

Heater Control Knob No.2

Heater Control Knob No.3

AVENSIS REPAIR MANUAL (RM1018E)

AIR CONDITIONING CONTROL ASSY

Air Conditioning Control Assy

Heater Control Housing

Cooler Wire No.1

Air Conditioning Panel Subassy

Control Knob Subassy

AVENSIS REPAIR MANUAL (RM1018E)

AIR CONDITIONING CONTROL ASSY

REMOVE AIR CONDITIONING CONTROL ASSY

REMOVE AIR CONDITIONING PANEL SUBASSY

AVENSIS REPAIR MANUAL (RM1018E)

AIR CONDITIONING CONTROL ASSY

Disconnect the cooler wire No.1 as shown in the illustration.

HEATER CONTROL KNOB NO.3 (MANUAL AIR CONDITIONING)

REMOVE HEATER CONTROL HOUSING (MANUAL

REMOVE HEATER CONTROL LENS ASSY (MANUAL AIR CONDITIONING)

AVENSIS REPAIR MANUAL (RM1018E)

REMOVE AIR CONDITIONING CONTROL BULB

AIR CONDITIONING CONTROL ASSY

REMOVE HEATER CONTROL HOUSING SUBASSY (MANUAL AIR CONDITIONING)

REMOVE HEATER CONTROL HOUSING

REMOVE COOLER WIRE NO.1

AVENSIS REPAIR MANUAL (RM1018E)

AIR CONDITIONING RADIATOR ASSY

AIR CONDITIONING RADIATOR ASSY

Defroster Nozzle Assy

Heater To Register Duct No.1

9.8 (100, 87 in.lbf)

9.8 (100, 87 in.lbf)

Air Conditioning Radiator Assy

9.8 (100, 87 in.lbf)

Instrument Panel Brace Subassy No.1

Air Duct Rear No.4

AVENSIS REPAIR MANUAL (RM1018E)

AIR CONDITIONING RADIATOR ASSY

Cooler Thermistor No.1

Cooler Air Hose

Air Duct No.1

Airmix Damper Servo Subassy

w/o Hot gas heater:

Cooler Unit Drain Hose No.1

w/o Hot gas heater:

w/ Hot gas heater:

Heater Radiator Unit Subassy

Nm (kgfcm, ftlbf)

AVENSIS REPAIR MANUAL (RM1018E)

AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM

DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

AVENSIS REPAIR MANUAL (RM1018E)