Page 2962 of 5135
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.
Page 2963 of 5135
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.
Page 2964 of 5135
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.
Page 2965 of 5135
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.
Page 2966 of 5135
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 Nm (35 kgfcm, 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 Nm (100 kgfcm, 87 in.lbf)
Page 2967 of 5135
I35299
I06878
ConnectGapWrong
±
HEATER & AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY
55±63
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the 2 nuts.
(c) Connect the connectors and the clip.
36. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting surface of the cooler refrigerant suction hose No.1.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the 2 O±rings on the cooler refrigerant suction hose No.1.
(d) Install the cooler refrigerant suction hose No.1 and piping clamp.
HINT:
After the connection, check the claw fitting of the piping clamp.
37. INSTALL LIQUID TUBE SUB±ASSY A
(a) Remove the attached vinyl tape from the tube.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting sur\
face of the liquid tube sub±assy A.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the 2 O±rings on the liquid tube sub±assy A.
(d) Install the liquid tube sub±assy A and the piping clamp.
HINT:
After the connection, check the claw fittings of the piping clamp.
38. ADD ENGINE COOLANT 3ZZ±FE/1ZZ±FE: (See page 16±7)
1AZ±FSE: (See page 16±31)
1AZ±FE: (See page 16±19)
1CD±FTV: (See page 16±44)
39. CHECK FOR ENGINE COOLANT LEAKS 3ZZ±FE/1ZZ±FE: (See page 16±1)
1AZ±FSE: (See page 16±25)
1AZ±FE: (See page 16±13)
1CD±FTV: (See page 16±37)
40.CHARGE REFRIGERANT (See page 55±38) SST 07110±58060 (07117±58060, 07117±58070, 07117±58080, 07117±58090, 07117±78050, 07117±88060, 07117±88070, 07117±88080)
Specified amount: 440 30 g (15.51 1.06 oz.)
41.WARM UP ENGINE (See page 55±38)
42.INSPECT LEAKAGE OF REFRIGERANT (See page 55±38)
Page 3148 of 5135
69067±02
B67410
± COMMUNICATION SYSTEMHIGH PITCHED HORN ASSY
69±5
AVENSIS REPAIR MANUAL (RM1018E)
HIGH PITCHED HORN ASSY
REPLACEMENT
1. REMOVE HIGH PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL HIGH PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator support
upper, and then install the horn with the bolt.
Torque: 20 Nm (204 kgfcm, 15 ftlbf)
(b) Connect the connector.
Page 3149 of 5135
69068±02
B67411
69±4
± COMMUNICATION SYSTEMLOW PITCHED HORN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
LOW PITCHED HORN ASSY
REPLACEMENT
1. REMOVE LOW PITCHED HORN ASSY
(a) Disconnect the connector.
(b) Remove the bolt and horn.
2. INSTALL LOW PITCHED HORN ASSY
(a) Place the stay onto the baffle part in the radiator support
upper, and then install the horn with the bolt.
Torque: 20 Nm (204 kgfcm, 15 ftlbf)
(b) Connect the connector.
