Content .. 101 102 103 104 ..

Toyota Corolla (2004+). Manual - part 103

55-35

HEATER & AIR CONDITIONER

- COOLER COMPRESSOR ASSY

(b) Using a vise pliers, hold the magnet clutch hub.

(c)

Remove the bolt, magnet clutch hub and magnet clutch

washer.

I32422

(d) Using a snap ring expander, remove the snap ring and

magnet clutch rotor.

(e) Remove the screw, disconnect the connector.

E37091

(f)

Using a snap ring expander, remove the snap ring and

magnet clutch starter.

E50116

REMOVE COOLER COMPRESSOR ASSY

INSTALL MAGNET CLUTCH ASSY

(a) Matching the parts shown in the illustration, install the

magnet clutch starter.

I32460

55-36

HEATER & AIR CONDITIONER

- COOLER COMPRESSOR ASSY

(b) Using a snap ring expander, install a new snap ring with

the chamfered side facing up.

(c)

Install the screw, connect the connector.

I32461

(d) Using a snap ring expander, install the magnet clutch ro-

tor 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 wash-

ers used before disassembly.

I31582

(f)

Using a vise pliers, hold the magnet clutch hub and install

the bolt.

Torque: 18 N m (183 kgf cm, 13 ft lbf)

I32423

10. INSPECT MAGNETIC CLUTCH CLEARANCE

(a) Set the dial indicator to the magnet clutch hub.

(b) Connect the battery positive lead to the terminal 1 of mag-

net 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.)

I32424

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.

55-37

HEATER & AIR CONDITIONER

- COOLER COMPRESSOR ASSY

11. INSPECT COMPRESSOR OIL

(a) When replacing the compressor and magnetic clutch with new one, after gradually removing the refrig-

erant gas from the service valve, drain the following amount of oil from the new compressor and mag-

netic clutch before installation.

Standard:

(Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.) ) - (Re-

maining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be re-

moved when replacing)

NOTICE:

When checking the compressor oil level, observe the precautions on the cooler removal/instal-

lation.

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, pre-

venting heat exchange in the refrigerant cycle and causing refrigerant failure.

If the remaining oil in the removed compressor and magnetic clutch is too small in volume,

check for oil leakage.

Be sure to use ND-OIL8 for compressor oil.

12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

(a) Install the compressor and magnetic clutch with the 3

bolts.

(1)

Toque: 29 N m (295 kgf cm, 21 ft lbf)

NOTICE:

(2)

Tighten the bolts in following order shown in the illustra-

tion to install the compressor and magnetic clutch.

(b) Connect the connector.

(3)

I32421

13. INSTALL DISCHARGE HOSE SUB-ASSY

(a) Remove the attached vinyl tape from the hose.

(b) Sufficiently apply compressor oil to the new O-ring and

fit surface of the compressor and magnetic clutch.

Compressor oil: ND-OIL8 or equivalent

(c)

Install a O-ring to the discharge hose sub-assy.

(d) Install the discharge hose sub-assy to the compressor

and magnetic clutch with the bolt.

Torque: 9.8 N m (100 kgf cm, 87 in. lbf)

I32459

55-38

HEATER & AIR CONDITIONER

- COOLER COMPRESSOR ASSY

14. INSTALL COOLER REFRIGERANT SUCTION HOSE

NO.1

(a) Remove the attached vinyl tape from the hose.

(b) Sufficiently apply compressor oil to the new O-ring and

fit surface of the compressor and magnetic clutch.

Compressor oil: ND-OIL8 or equivalent

(c)

Install a O-ring to the cooler refrigerant suction hose No.

(d) Install the cooler refrigerant suction hose No. 1 to the

compressor and magnetic clutch with the bolt.

Torque: 9.8 N m (100 kgf cm, 87 in. lbf)

I32458

15. CHARGE REFRIGERANT (See page 55-11)

SST

07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,

07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140

Specified amount: 490

30 g (17.28

1.06 oz.)

16. WARM UP ENGINE

17. INSPECT LEAKAGE OF REFRIGERANT (See page 55-11)

55-13

HEATER & AIR CONDITIONER

- HEATER CONTROL & ACCESSORY ASSY

HEATER CONTROL & ACCESSORY ASSY

550IT-01

REPLACEMENT

REMOVE CONSOLE PANEL UPPER (See page 71-10)

REMOVE INSTRUMENT CLUSTER FINISH PANEL (See page 71-10)

REMOVE HEATER CONTROL & ACCESSORY ASSY

(a) Release the 2 fitting claws and pull out the heater control

& accessory assy.

2 Claws

I32427

(b) Using a screwdriver, open the claw of the cable clamp and

disconnect the defroster damper control cable.

NOTICE:

Be careful not to bend the cable wire.

If the cable wire bends, the heater control & accesso-

ry assy operationality becomes worse.

HINT:

Tape the screwdriver tip before use.

I32428

(c)

Using a screwdriver, open the claw of the cable clamp and

disconnect the air mix damper control cable.

NOTICE:

Be careful not to bend the cable wire.

If the cable wire bends, the heater control & accesso-

ry assy operationality becomes worse.

HINT:

Tape the screwdriver tip before use.

I32429

(d) Disconnect the connector, remove the heater control &

accessory assy.

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:

Be careful not to bend the cable wire.

If the cable wire bends, the heater control & accesso-

I32430

ry assy operationality becomes worse.

55-14

HEATER & AIR CONDITIONER

- HEATER CONTROL & ACCESSORY ASSY

HINT:

Operating the heater control knob and check that it prop-

erly 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)

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:

Be careful not to bend the cable wire.

If the cable wire bends, the heater control & accesso-

ry assy operationality becomes worse.

I32431

HINT:

Operating the heater control knob and check that it prop-

erly stops at both ends of FACE and DEF 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.

(e) Connect the connector, install the heater control & acces-

sory assy.

55-3

HEATER & AIR CONDITIONER

- AIR CONDITIONING SYSTEM

550IP-01

INSPECTION

COOLER THERMISTOR NO.1

(a) Check resistance between terminals 1 and 2 of cooler

thermistor No. 1 at each temperature, as shown in the

chart.

Resistance:

I32480

Resistance (kW)

–30 -20 -10

Temperature (FC)

I30145

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

55-4

HEATER & AIR CONDITIONER

- AIR CONDITIONING SYSTEM

COOLER AND ACCESSORY ASSY

(a) Inspect blower switch continuity.

Condition / Circuit

Tester connection

Specified condition

OFF

No continuity

1 - 8

Continuity

1 - 6 - 8

Continuity

1 - 5 - 8

Continuity

1 - 4 - 8

Continuity

E37726

If continuity is not as specified, replace the air conditioner con-

trol 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.

COOLER SWITCH HOLE COVER

(a) Inspect switch continuity.

Check the continuity between terminals while switch is

pressed, as shown in the chart.

Tester connection

Specified condition

2 - 5

Continuity

If continuity is not as specified, replace the cooler switch.

(b) Inspect illumination operation.

E50533

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 ter-

minal 2 and the negative (-) lead to terminal 1.

(2)

Push the A/C button in and then check that the indi-

cator 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 ter-

minal 2 and the negative (-) lead to terminal 1 while

press the switch.

(2)

Connect the positive (+) lead from battery to termi-

nal 4 and then check that the indicator dims.

If operation is not as specified, replace the cooler switch.

55-5

HEATER & AIR CONDITIONER

- AIR CONDITIONING SYSTEM

BLOWER RESISTOR

(a) Measure resistance between terminals, as shown in the

chart below.

Tester connection

Specified condition

1 - 2

1.398 - 1.605 W

1 - 3

0.465 - 0.535 W

1 - 4

3.069 - 3.531 W

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

E32877

BLOWER W/FAN MOTOR SUB-ASSY

(a) 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

HEATER BLOWER MOTOR RELAY ASSY

Condition

tester connection

Specified condition

1 - 2

constant

Continuity

3 - 4

Apply B+ between

3 - 5

Continuity

terminals 1 and 2.

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

relay.

E32993

MAGNET-CLUTCH RELAY

Condition

tester connection

Specified condition

constant

1 - 2

Continuity

Apply B+ between

3 - 5

Continuity

terminals 1 and 2.

If continuity is not as specified, replace the magnet-clutch relay.

I30152

55-2

HEATER & AIR CONDITIONER

- AIR CONDITIONING SYSTEM

550IO-01

ON-VEHICLE INSPECTION

INSPECT PRESSURE SWITCH NO.1.

(a) 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 refriger-

Low pressure side

High pressure side

ant pressure is changed, as shown in the illustra-

ON (Continuity)

tion.

If operation is not as specified, replace the pressure switch.

196 kpa

3,140 kpa

(132.0 kgf/cm2 455 psi)

(2.0 kgf/cm2 28 psi)

OFF (No continuity) OFF (No continuity)

I30146

(b) 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 refriger-

ant pressure is changed, as shown in the illustra-

tion.

If operation is not as specified, replace the pressure switch.

1,226 kpa

(12.5 kgf/cm2 178 psi)

OFF

(Continuity)

(No continuity)

1,520 kpa

(15.5 kgf/cm2 220 psi)

I30291

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.

55-1

HEATER & AIR CONDITIONER

- AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM

550IN-01

PRECAUTION

DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

AREA OR NEAR AN OPEN FLAME

ALWAYS WEAR EYE PROTECTION

AC2810

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

AC2811

treatment.

NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED

FLAME

BE CAREFUL NOT TO DROP CONTAINER AND NOT

TO APPLY PHYSICAL SHOCKS TO IT

DO NOT OPERATE COMPRESSOR WITHOUT

Wrong

Okay

ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM

If there is not enough refrigerant in the refrigerant system oil lu-

LO HI

brication will be insufficient and compressor burnout may occur,

so take care to avoid this, necessary care should be taken.

DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE

WHILE COMPRESSOR IS OPERATING

If the high pressure valves opened, refrigerant flows in the re-

N11084

verse direction and could cause the charging cylinder to rup-

ture, so open and close the only low pressure valve.

BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH

REFRIGERANT

If refrigerant is overcharged, it causes problems such as insuffi-

cient cooling, poor fuel economy, engine overheating etc.

55-12

HEATER & AIR CONDITIONER

- REFRIGERANT LINE

REFRIGERANT LINE

550IS-01

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 Sub-assy

Nm (kgfcm, ftlbf)

: Specified torque

I32213

55-6

HEATER & AIR CONDITIONER

- REFRIGERANT

REFRIGERANT

550IQ-01

ON-VEHICLE INSPECTION

INSPECT REFRIGERANT PRESSURE WITH MAN-

IFOLD GAUGE SET

(a) 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:

Temperature at the air inlet with the switch set

at RECIRC is 30 - 35 °C (86 - 95 °F)

Engine running at 1500 rpm

Blower speed control switch at ”HI” position

Temperature control dial at ”COOL” position

A/C switch ON

Fully open doors

(1)

Normally functioning refrigeration system.

Gauge reading:

Low pressure side:

0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm 2)

High pressure side:

1.37 - 1.57 MPa (14 - 16 kgf/cm 2)

E50573

(2)

Moisture present in refrigeration system.

Condition : Periodically cools and then fails to cool

I22117

Symptom

Probable cause

Diagnosis

Remedy

Moisture in refrigerating system

F Drier in oversaturected state

(1) Replace condenser

During operation, pressure on low

freezes at expansion valve orifice

F Moisture in refrigerating system

(2) Remove moisture in cycle by

pressure side sometimes become

causing a temporary stop of cycle,

freezes at expansion valve orifice

repeatedly evacuating air

a vacuum and sometime normal

however, when it melts, normal

and blocks circulation of refriger-

(3) Supply proper amount of new

state is restored.

ant

refrigerant

55-7

HEATER & AIR CONDITIONER

- REFRIGERANT

(3)

Insufficient cooling

Condition: Cooling system does not function eftectively.

I22118

Symptom

Probable cause

Diagnosis

Corrective Actions

(1) Check for gas leakage and re-

pair if necessary

(2) Supply proper amount of new

F Pressure low on both low and

refrigerant

Gas leakage in refrigeration sys-

F Insufficient refrigerant

high pressure sides

(3) If indicated pressure value is

tem

F Refrigerant leaking

F Insufficient cooling performance

close to a 0 when connected to

gauge, create the vacuum after in-

specting and repairing location of

leak

(4)

Poor circulation of refrigerant

Condition: Cooling system close not function effectively.

I22119

Symptom

Probable cause

Diagnosis

Corrective Action

F Pressure low on both low and

high pressure sides

Refrigerant flow obstructed by dirt

Receiver clogged

Replace condenser

F Frost on pipe from condenser to

in receiver

unit

55-8

HEATER & AIR CONDITIONER

- REFRIGERANT

(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

F Vacuum indicated on low pres-

F Refrigerant flow obstructed by

valve by air blowing

sure side, very low pressure indi-

moisture or dirt in refrigerating sys-

(3) Replace condenser

cated on high pressure side

tem

Refrigerant does not circulate

(4) Evaporate air and supply prop-

F Frost or dew seen on piping be-

F Refrigerant flow obstructed by

er amount of new refrigerant.

fore and after receiver/ drier or ex-

gas leaked from expansion valve

(5) For gas leakage from expan-

pansion valve

sion valve, replace expansion

valve

(6)

Refrigerant overcharged or insufficient cooling of

condenser

Condition: Cooling system does not function dftectively.

I22121

Symptom

Probable cause

Diagnosis

Remedy

(1) Clean condenser

F Excessive refrigerant in

(2) Check cooling fan with cooling

F Unable to develop sufficient per-

cycletoo much refrigerant sup-

fan motor operation

F Pressure too high on both low

formance due to excessive use of

plied

(3) If (1) and (2) are in normal

and high pressure sides

refrigerating system

F Condenser cooling

state, check amount of refrigerant

F Insufficient cooling of condenser

insufficientcondenser fins

and supply proper amount of re-

clogged at cooling fan

frigerant

Content .. 101 102 103 104 ..