2002 TOYOTA AVENSIS Repair Manual

I30081
0.5 (5.0)
0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Blower HI Zone
Blower LO Zone
MPa (kgf/cm
2) Pressure on HI
pressure side 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0)1.06 (10.9)
0.27 (2.85)
0.22 (2.25)
0.2 (2.1)
0.14 (1.5)1.2 (12.3)
1.25 (12.8)
1.32 (13.5)
± HEATER & AIR CONDITIONERREFRIGERANT
55±25
AVENSIS REPAIR MANUAL (RM1018E)
2. w/o Hot gas heater:
INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the manifold gauge pressure
when the following conditions are fullfilled.
Test conditions:

Engine has been warmed up.

All doors are fully open.

A/C switch is ON.

Engine is running at 1,500 rpm.

Air inlet mode selector switch is at RECIRE.

Temperature control dial is at ºMAX. COOLº.

Blower speed control switch is at ºHIº.

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

E50573
I22117
Condition : Air conditioning system periodically repeats proper and improper function. 55±26
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(1) When the refrigerant volume is proper:
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)
(2) When there is moisture in the refrigeration system:
SymptomProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side cycles between nor-
mal and vacuum
Moisture in refrigeration system
freezes at expansion valve orifice,
causing a temporary stop of cycle.
However, when it melts, normal
state is restored
Drier is overly saturated

Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace cooler drier
(2) Remove moisture in cycle by
repeatedly vacuuming
(3) Supply proper amount of new
refrigerant

I22118
Condition: Air conditioning system does not function effectively.
I22119
Condition: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±27
AVENSIS REPAIR MANUAL (RM1018E)
(3) When cooling is insufficient:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is low on both low and
high pressure sides

RHD AZ engine series:
Bubbles are seen through sight
glass continuously

Cooling performance is insuffi-
cient
Gas leakage in refrigeration sys-
tem
Insufficient refrigerant

Refrigerant leakage
(1) Check for gas leakage and re-
pair if necessary
(2) Supply proper amount of new
refrigerant
(3) If indicated pressure value is
close to 0 when connected to the
gauge, vacuum after inspecting
and repairing the location of leak-
age.
(4) When the circulation of the refrigerant is poor:
SymptomProbable causeDiagnosisCorrective Action

Pressure is low on both low and
high pressure sides

Frost exists on piping from con-
denser to A/C unit
Refrigerant flow is obstructed by
dirt in condenserCondenser is cloggedReplace condenser

I22120
Condition: Air conditioning system does not function. (Sometimes it may function)
I22121
Condition : Air conditioning system does not function effectively. 55±28
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(5) When the refrigerant does not circulate:
SymptomProbable causeDiagnosisCorrective Actions

Vacuum is indicated on low pres-
sure side, and extreamly low pres-
sure is indicated on high pressure
side

Frost or dew is seen on piping on
both sides of condenser or expan-
sion valve

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

Refrigerant flow is obstructed by
gas leak from expansion valve
Refrigerant does not circulate
(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 expan-
sion valve, replace expansion
valve
(6) When the refrigerant is overcharged or cooling of
condenser is insufficient:
SymptomProbable causeDiagnosisRemedy

Pressure is extreamly high on
both low and high pressure sides

RHD AZ engine series:
No air bubbles are seen through
sight glass even when engine rpm
lowers

Excessive refrigerant

Cooling performance of con-
denser is insufficient
Excessive refrigerant

Cooling performance of con-
denser is insufficient
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check the amount of refrig-
erant and supply proper amount of
refrigerant

I22122
Condition: Air conditioning system does not function.
NOTE : These gauge indica-
tions occur when the refrigera-
tion system opens and the re-
frigerant is charged without
vacuuming.
I22123
Condition
: Air conditioning system does not function effectively.
± HEATER & AIR CONDITIONERREFRIGERANT
55±29
AVENSIS REPAIR MANUAL (RM1018E)
(7) When there is air in the refrigeration system:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and the high pressure
sides

The low pressure piping is too
hot to touch

RHD AZ engine series:
Bubbles can be seen through sight
glass
Air in refrigeration system

There is air in refrigeration sys-
tem

Vacuuming is insufficient
(1) Check it compressor oil is dirty
or insufficient
(2) Vacuum and supply new refrig-
erant
(8) When the expansion valve malfunctions:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and high pressure sides

Frost or dew is on piping on low
pressure side
Trouble with expansion valve

Excessive refrigerant in low
pressure piping

Expansion valve opened too
wide
Replace expansion valve

I22124
Condition
: Air conditioning system does not function. 55±30
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
(9) When the compressor is defective:
SymptomProbable causeDiagnosisCorrective Actions

Pressure is extreamly high on
both low and high pressure sides

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

Compression failure

Leakage from damaged valve or
broken sliding parts
Repair or replace compressor

± 50 g (± 1.76 oz.)
I37057
0.1 (1.0)0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Outside temperature 0
C (F) 15 (59) 20 (68) 30 (86)25 (77) 35 (95)
0 g (0 oz.)
(Standard)
+ 50 g (+ 1.76 oz.)
± HEATER & AIR CONDITIONERREFRIGERANT
55±31
AVENSIS REPAIR MANUAL (RM1018E)
3. w/ Hot gas heater:
INSPECT REFRIGERANT VOLUME
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the the manifold gauge pres-
sure when these conditions are established.
Test conditions:

Engine is at idle.

Blower speed control switch is at ºHIº.

Temperature control dial is at ºMAX. COOLº.

Engine has been warmed up.

All doors are fully open.

Hood is fully open.

Air inlet mode selector damper is at RECIRE.

Air outlet damper is at FACE.

Outside temperature is 15 ± 35
C (59± 95

F).
(b) Check refrigerant volume according to the graph below.
RangeAmount of refrigerantCorrective actions
Except range belowInsufficient or excessive
Supply refrigerant until low
pressure become within
the standard
50 g
(
1.76 oz.), or remove
refrigerant and then sup-
ply proper amount of re-
frigerant
Standard
50 g
(
1.76 oz.)Proper±

I30081
0.5 (5.0)
0.4 (4.0)
0.3 (3.0)
0.2 (2.0)MPa (kgf/cm
2) Pressure on low pressure side
Blower HI Zone
Blower LO Zone
MPa (kgf/cm
2) Pressure on HI
pressure side 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0)1.06 (10.9)
0.27 (2.85)
0.22 (2.25)
0.2 (2.1)
0.14 (1.5)1.2 (12.3)
1.25 (12.8)
1.32 (13.5) 55±32
± HEATER & AIR CONDITIONERREFRIGERANT
AVENSIS REPAIR MANUAL (RM1018E)
4. w/ Hot gas heater:
INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
(a) This is a method to specify the trouble area by using a
manifold gauge set. Read the manifold gauge pressure
when the following conditions are fullfilled.
Test conditions:

Engine has been warmed up.

All doors are fully open.

A/C switch is ON.

Engine is at idle.

Air inlet mode selector damper is at RECIRE.

Temperature control dial is at ºMAX. COOLº.

Blower speed control switch is at ºHIº.

Air outlet damper is at FACE.

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

Sunshine is shut off.
Gauge readings (Reference)