2005 TOYOTA AVENSIS air conditioning

550YW±01
I03839
PushSST Pull
Release
Lever
I06919
Screw
Driver
Disconnect the
tube using hand
I35293
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
55±55
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
COMPONENTS: See page 55±53
1.DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55±38)
SST 07110±58060 (07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080) 2. DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1
(a) Install SST on the piping clamp. SST 09870±00025
HINT:
Make sure the direction of the piping clamp claw and SST by
checking the illustration shown on the caution label.
(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, and then re- move the piping clamp with SST.
(d) Disconnect the cooler refrigerant suction hose No.1.
NOTICE:

Do not use a screwdriver or similar tool to disconnect
the tube.

Seal the opening of the disconnected parts using vi-
nyl tape to prevent moisture and foreign matter from
entering.
3. DISCONNECT LIQUID TUBE SUB±ASSY A SST 09870±00015
HINT:
Disconnection of the liquid tube sub±assy A is the same as the cooler\
refrigerant suction hose No.1.
4. DISCONNECT HEATER INLET WATER HOSE
(a) Using pliers, grip the claws of the clip and slide the clip todisconnect the heater inlet water hose.

I352944 Claws
Clamp
I352955 Claws
I352966 Claws
I35297
6 Claws
55±56
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5.DISCONNECT HEATER OUTLET WATER HOSE
HINT:
Disconnection of the heater outlet water hose is the same way as the hea\
ter inlet water hose.
6.REMOVE INSTRUMENT PANEL LOWER ASSY (See page 71±11)
HINT:
Refer to the instructions for removal of the instrument panel lower assy\
.
7.REMOVE ECM (See page 10±65) 8. REMOVE HEATER TO REGISTER DUCT NO.1
(a) Remove the 2 clips and screw.
(b) Release the 4 claw fittings and the clip and remove theheater to register duct No.1.
9. REMOVE DEFROSTER NOZZLE ASSY
(a) Release the 5 claw fittings and remove the defroster nozzle assy.
10. REMOVE AIR DUCT REAR NO.3
(a) Release the 6 claw fittings and remove the air duct rear No.3.
11. REMOVE AIR DUCT REAR NO.4
(a) Release the 6 claw fittings and remove the air duct rear No.4.

I352984 Clamps
I35299
I36809
I35300
I36810Clamp
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±57
AVENSIS REPAIR MANUAL (RM1018E)
12. REMOVE INSTRUMENT PANEL BRACE SUB±ASSY
NO.1
(a) Disconnect the 4 clamps.
(b) Remove the 2 bolts, the screw, the nut and the instrument
panel brace sub±assy No.1.
13. REMOVE AIR CONDITIONER UNIT ASSY
(a) Disconnect the connectors and the clip.
(b) Remove the 2 nuts.
(c) PTC Heater model:
Remove the bolt.
(d) Remove the 2 bolts, the 2 nuts and the air conditioner unit
assy.
14. REMOVE AIR CONDITIONING RADIATOR ASSY
(a) Disconnect the clamp.

I36811Clamp
I35301
I353022 Claws
I353032 Claws
I35304
55±58
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(b) RHD Auto A/C:
Disconnect the clamp.
(c) Remove the 3 screws and air conditioning radiator assy.
15. REMOVE AIR DUCT NO.1
(a) Release the 2 claw fittings and remove the air duct No.1.
16. REMOVE AIR DUCT NO.2
(a) Release the 2 claw fittings and remove the air duct No.2.
17. REMOVE MODE DAMPER SERVO SUB±ASSY
(a) Remove the 3 screws and the mode damper servo sub±
assy.

I35305
I353063 Claws


I35835
LHD:
RHD:4 Claws
I35308
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±59
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE AIRMIX DAMPER SERVO SUB±ASSY
(a) Remove the 2 screws and the airmix damper servo sub±
assy.
19. REMOVE HEATER PIPING COVER
(a) Release the 3 claw fittings and remove the heater piping
cover.
20. REMOVE HEATER RADIATOR UNIT SUB±ASSY
(a) LHD:
Release the 4 claw fittings and remove the clamp.
(b) RHD:
Remove the screw and the clamp.
(c) Remove the heater radiator unit sub±assy.

I35309
I35310Claw
I35311

I37394
55±60
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
21. REMOVE AIR CONDITIONING WIRENO1 (AUTO AIR CONDITIONING)
22. REMOVE AIRMIX NO.2 DAMPER SERVO SUB±ASSY
(AUTO AIR CONDITIONING)
(a) Remove the 2 screws and the airmix No.2 damper servo
sub±assy.
23. REMOVE AIR CONDITIONING TUBE ASSY
(a) Remove the 2 screws.
(b) Release the claw fitting and remove the cover.
(c) Using a hexagon wrench 4.0 mm (0.15 in.), remove the
2 hexagon bolts and the air conditioning tube assy.
(d) w/o Hot gas heater:
Remove the 2 O±rings from the air conditioning tube assy.
24. REMOVE COOLER EXPANSION VALVE (W/O HOT
GAS HEATER)
(a) Remove the cooler expansion valve from the cooler evap-
orator sub±assy No.1.

I35313
I33489
I36814
I33489
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
55±61
AVENSIS REPAIR MANUAL (RM1018E)
25. REMOVE COOLER THERMISTOR NO.1
(a) Remove the 6 screws and the cover.
(b) Remove the cooler thermistor No.1 and the cooler evapo-
rator sub±assy No.1 from the case.
(c) Remove the cooler thermistor No.1 from the cooler evap-
orator sub±assy No.1.
26. REMOVE COOLER EVAPORATOR SUB±ASSY NO.1
(a) Remove the 2 O±rings from the cooler evaporator sub±
assy No.1.
27. REMOVE COOLER AIR HOSE
(a) Remove the screw and the cooler air hose.
28. REMOVE AIR DUCT ASSY HEATER
29. REMOVE COOLER AIR HOSE (AUTO AIR CONDITIONING)
30. REMOVE COOLER UNIT DRAIN HOSE NO.1
31. INSTALL COOLER EVAPORATOR SUB±ASSY NO.1
(a) Sufficiently apply compressor oil to 2 new O±rings and the
fitting surface of the cooler expansion valve.
Compressor oil: ND±OIL 8 or equivalent
(b) Install the 2 O±rings on the cooler evaporator sub±assy
No.1.

I36812
107 mm
(4.21 in.)
201 mm (7.91 in.)
67 mm
(2.63 in.)
50 mm
(1.96 in.)
I35313

I37394
I35311
I35300
55±62
± HEATER & AIR CONDITIONERAIR CONDITIONING RADIATOR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
32. INSTALL COOLER THERMISTOR NO.1
(a) Install the cooler thermistor No.1 as shown in the illustra-
tion.
(b) Install the cooler evaporator sub±assy No.1 on the case.
(c) Install the cover with the 6 screws.
33. INSTALL COOLER EXPANSION VALVE (W/O HOT
GAS HEATER)
(a) Install the cooler expansion valve.
34. INSTALL AIR CONDITIONING TUBE ASSY
(a) w/o Hot gas heater:
Sufficiently apply compressor oil to 2 new O±rings and the
fitting surface of the air conditioning tube assy.
Compressor oil: ND±OIL 8 equivalent
(b) w/o Hot gas heater:
Install the 2 O±rings on the air conditioning tube assy.
(c) Using a hexagon wrench 4.0 mm (0.15 in.), install the air
conditioning tube assy with the 2 hexagon bolts.
Torque: 3.5 N
m (35 kgf
cm, 30 in.
lbf)
35. INSTALL AIR CONDITIONER UNIT ASSY
(a) Install the air conditioner unit assy with the 2 bolts and 2
nuts.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)