AIR CONDITIONING - Toyota-Tech.eu

HFC 134aZZT22#R (1ZZ-FE / 3ZZ-FE) / AZT220R (1AZ-FE)FOR EUROPEAN SPEC.AIR CONDITIONINGENGLISHAAAMU-63INSTALLATION MANUALiendly RefrFrrantigeOzoneINSIDE ENGINE COMPARTMENTAAAMU-63

AAAMU-63 2000(EUROPE) B.V.All Rights Reserved. This book, parts thereof, maynot be reproduced or copied in any form withoutthe written permission of the publisher.

AAAMU-63INTRODUCTIONIMPORTANT NOTICEThis manual has been designed for technicians who are qualified and educated in the proper procedures of vehicle safety,handling and maintenance; experienced in installation of car air conditioning or who are able to carry out installationprocedures when given instructions by an experienced technician in a supervisory capacity; and are certified to handlingrefrigerant.1. Take special care to ensure that clearance between air conditioning components and other components such as brakeparts, fuel system and electric wires as specified in this manual.2. If a problem is found with the air conditioning system due to installation, refer back to the manual to correct theproblem(s).3. Vehicle and air conditioning kit components as well as installation procedures are subject to change without priornotice. Refer to the latest installation manual and service information. Any changes affecting the above items will begiven in the form of an "Installation instructions for air conditioning (Supplement)" (issued by DENSO) or a servicebulletin (issued by the manufacturer).DEFINITION OF TERMSWARNING: Describes precautions that should be observed in order to prevent injury or death to the userduring installation.: Describes precautions that should be observed in order to prevent damage to the vehicle or itscomponents, which may occur during installation if insufficient care is taken.: Provides additional information that facilitates installation work.CAUTIONNOTEFRONT, REARLEFT, RIGHT: Shows the direction when viewed from the driver's seatFOREWORDThis manual has been published to explain how to install the air conditioning for TOYOTA AVENSIS.When installing the air conditioning, installation should be performed as described in this manual.[APPLICATION VEHICLE]VEHICLE NAMEAVENSISMODEL CODEZZT221RZZT220RAZT220RPRODUCTION PERIODENGINE TYPESTEERING POSITIONDESTINATION2000.07--- 1ZZ-FE3ZZ-FE1AZ-FERHDEUROPECAUTION1. Carefully read the separate manual "GENERAL INFORMATION / AFTER INSTALLATION" before and afterinstallation. (Document code: AOAMU-02A / Document part number: 988963-3480)2. Refer to the separate manual "INSTALLATION MANUAL (INSIDE PASSENGER COMPARTMENT)" for details oninstallation for the passenger compartment side. (Document code: AAAMU-60 / Document part number: 9889634130)-1-

AAAMU-631. INSTALLATION INSIDE ENGINE COMPARTMENTCAUTION1. Before starting installation, remove the (–) terminal of the battery.2. Before making any hoses and tubes connections, apply a few drops of compressor oil to the seat of O-ring andcoupling nuts.3. When tightening and loosening the fittings, use two wrenches for support.4. Ensure fender covers are in position.fabcde(1) REMOVAL OF PARTS(a)(b)(c)(d)(e)(f)-2-Battery and battery carrier.Cover above grille.Front grille.Radiator upper supports.Under covers.Junction block cover.

AAAMU-63 1,3ZZ-FE E/G MODEL ONLY [(g)-(j)]i(g)(h)h(i)(j)gLoosen two clamps of vehicle harness.Disconnect vehicle harness connector on air filterbox upper cover.Disconnect VSV connector.Remove air filter box.j 1AZ-FE E/G MODEL ONLY [(k)-(u)]rqnpomlks(k)(l)(m)(n)(o)(p)(q)(r)Air pressure sensor.Relay box (if equipped).Disconnect VSV connector.Loosen VSV.Loosen clamp of vehicle harness on air filter box.Air filter box.Place air hose on top of the engine.Loosen clamp of vehicle harness.(s)(t)Disconnect vehicle harness connector.Loosen three clamps of vehicle harness.(u)Remove bracket of vehicle harness clamp.tu-3-

AAAMU-63(v)Disconnect ABS connector. 1AZ-FE E/G MODEL ONLY [(w)](w) Disconnect vehicle connector.vw(x)(y)Disconnect radiator fan connector.Remove radiator fan.xya1(2) CONDENSER(a)Insert the condenser (1), leaning the radiator (2)backward.CAUTION2Place a piece of corrugated board in front of the radiator.(b)b-4-Fasten the condenser to the radiator upper supportusing two nuts (black M6).

AAAMU-63(3) COMPRESSOR 1,3ZZ-FE E/G MODEL ONLY [(a)-(c)](a)Remove and discard the alternator belt from eachpulley.NOTESet the wrench as shown in the left figure, and removethe alternator belt from the pulleys while pulling thewrench to the front of the vehicle.1a1625(1)Front(1)(2)(3)(4)(5)(6)Alternator pulleyWater pump pulleyCrankshaft pulleyP/S pulleyAuto tensionerToward front(b)Install the compressor to the engine block usingthree bolts (M8 x 81).34Tightening torque:24.5 Nm (250 kgf.cm, 18.1 ft.lbf).1CAUTIONTightening order: 1 -- 2 -- 332b(c)Install the compressor drive belt to each pulley.NOTESet the wrench as shown in the left figure.c-5-

AAAMU-63NOTE17Install the compressor drive belt to each pulley exceptthe water pump pulley. Then pivot the belt auto tensionertoward the front (clockwise) of the vehicle and slide thecompressor drive belt onto the water pump pulley, thencarefully return the tensioner to its original position.26534(1)(2)(3)(4)(5)(6)(7)Alternator pulleyWater pump pulleyCompressor pulleyCrankshaft pulleyP/S pulleyAuto tensionerToward front 1AZ-FE E/G MODEL ONLY [(d)-(f)](d)Remove and discard the alternator belt from eachpulley.NOTEdSet the wrench as shown in the left figure, and removethe alternator belt from the pulleys while pulling thewrench to the front of the vehicle.(1)(2)(3)(4)(5)15243-6-Alternator pulleyWater pump pulleyCrankshaft pulleyAuto tensionerP/S pump pulley

AAAMU-63(e)31Install the compressor to the engine block usingfour bolts (M8 x 81).Tightening torque:24.5 Nm (250 kgf.cm, 18.1 ft.lbf).CAUTIONTightening order: 1 -- 2 -- 3 -- 4.42e(f)Install the compressor drive belt to each pulley.NOTESet the wrench as shown in the left figure.fNOTEInstall the compressor drive belt to each pulley exceptthe water pump pulley. Then pivot the belt auto tensionertoward the front (clockwise) of the vehicle and slide thecompressor drive belt onto the water pump pulley, thencarefully return the tensioner to its original position.126534(1)(2)(3)(4)(5)(6)-7-Alternator pulleyWater pump pulleyCompressor pulleyCrankshaft pulleyAuto tensionerP/S pump pulley

AAAMU-636Bolt gold M6 x 309.8 2.0 Nm100 20 kgf.cm7.2 1.3 ft.lbf1347532.3 2.0 Nm330 20 kgf.cm23.4 1.7 ft.lbf28Bolt black M6 x 305.4 1.0 Nm55 10 kgf.cm4.0 0.7 ft.lbfNut black M69.8 2.0 Nm100 20 kgf.cm7.2 1.3 ft.lbf(4) PIPING LAYOUT 1,3ZZ-FE E/G MODEL ONLY charge hose.Condenser.Liquid tube no.1.Liquid tube no.2.Evaporator.Suction tube.Suction hose.

AAAMU-63Bolt gold M6 x 309.8 2.0 Nm100 20 kgf.cm7.2 1.3 ft.lbf13.7 1.0 Nm140 10 kgf.cm9.8 1.0 ft.lbf14376859Nut black M69.8 2.0 Nm100 20 kgf.cm7.2 1.3 ft.lbf32.3 2.0 Nm330 20 kgf.cm23.4 1.7 ft.lbf210Bolt black M6 x 305.4 1.0 Nm55 10 kgf.cm4.0 0.7 ft.lbf 1AZ-FE E/G MODEL ONLY ssor.Discharge hose.Condenser.Liquid tube no.1.Liquid tube no.2.Liquid tube no.3.Evaporator.Suction tube no.1.Suction tube no.2.Suction hose.

AAAMU-63(a)Connect the discharge hose to the condenserusing a bolt (black M6 x 30).Tightening torque:5.4 1.0 Nm (55 10 kgf.cm / 4.0 0.7 ft.lbf).a(b)Install the bracket of the discharge hose to thebody using a bolt (gold M6 x 14).CAUTIONMake sure the bracket is in line with the dischargehose.NGbOK 1,3ZZ-FE E/G MODEL ONLY [(c)-(d)]c(c)Connect the discharge hose to the compressorusing a bolt (gold M6 x 30).Tightening torque:9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).(d)Connect the vehicle harness (3-P) to thecompressor.d 1AZ-FE E/G MODEL ONLY [(e)-(g)]e(e)Connect the discharge hose to the compressorusing a bolt (gold M6 x 30).Tightening torque:9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).f(f)g(g)- 10 -Connect the vehicle harness (3-P) to thecompressor.Fasten the O2 sensor harness to the dischargehose using a clamp.

AAAMU-63(h)Connect the liquid tube no.1 to the condenserusing a bolt (black M6 x 30).hTightening torque:5.4 1.0 Nm (55 10 kgf.cm / 4.0 0.7 ft.lbf) 1,3ZZ-FE E/G MODEL ONLY [(i)-(k)]kInstall the tubes according following order:j(i)(j)(k)Install the white clamp to the body.First put in position the liquid tube no.2 (1), thenput in position the suction tube (2).First install the large quick joint clamp to thesuction tube, then install the small quick jointclamp to the liquid tube no.2.i21 1AZ-FE E/G MODEL ONLY [(l)-(q)](l)l- 11 -Put a piece of packing on the bracket of the ABSunit.

AAAMU-63(m) Insert the suction tube no.1 to the evaporator andinstall the quick joint clamp.m(n)(o)(p)(q)noqInstall the white clamp to the body.Connect suction tube no.2 to suction tube no.1.Install the suction tube no.2 to the white clamp.Tighten the block fitting of suction tube no.1 andsuction tube no.2.Tightening torque:9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).p(r)rConnect the suction hose to the suction tube usingthe union type coupling.Tightening torque:32.3 2.0 Nm (330 20 kgf.cm, 23.4 1.7 ft.lbf). 1,3ZZ-FE E/G MODEL ONLY [(s)]s(s)Connect the suction hose to the compressor usinga bolt (gold M6 x 30).Tightening torque:9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).- 12 -

AAAMU-63 1AZ-FE E/G MODEL ONLY [(t)-(v)]t(t)Connect the suction hose to the compressor usinga bolt (gold M6 x 30).Tightening torque:9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).(u)Connect liquid tube no. 3 to the evaporator andinstall the quick joint clamp.(v)Connect liquid tube no. 2 to liquid tube no. 3.uvTightening torque:13.7 1.0 Nm (140 10 kgf.cm / 9.8 1.0 ft.lbf).- 13 -

AAAMU-63(w) Install the suction hose to the bracket of liquid tubeno.2.w(x)Connect the liquid tube no.1 to the liquid tube no.2using a nut (black M6).xTightening torque:9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).(y)Install the bracket of liquid tube no. 2 to the bodyusing 2 bolts (gold M6 x 14).(z)Install the bracket of the suction hose to thecrossmember using a nut (black M6).yz- 14 -

AAAMU-63(5) SPECIFIED TIGHTENING TORQUESTighten union type coupling at the specified torque:Tube 5/8" : 32.3 2.0 Nm (330 20 kgf.cm / 23.4 1.7 ft.lbf).Tube 8 mm: 13.7 1.0 Nm (140 10 kgf.cm / 9.8 1.0 ft.lbf).Tighten the bolts of the tubes and hoses to the:Compressor : 9.8 2.0 N·m (100 20 kgf.cm / 7.2 1.3 ft.lbf).Condenser : 5.4 1.0 Nm (55 10 kgf.cm / 4.0 0.7 ft.lbf)(6) PRESSURE SWITCH(a)Connect the vehicle harness (4-P) to the pressureswitch.a(7) CONDENSER FAN(a)(b)ba- 15 -Reinstall the radiator fan.Reconnect radiator fan connector.

AAAMU-63(c)c(d)Install the condenser fan behind the radiator usingthree bolts (silver M6 x 16)Connect the vehicle harness (2-P) to the condenserfan.d(8) JUNCTION BLOCK123a(a)Install three relays:(1)(2)(3)Black relayBlack relayOrange relay(9) CAUTION LABELR134a USEONLY8(a)R134a UAttach the caution label to the engine hood.SE ONLY8(10) REINSTALLATION(a)- 16 -Reinstall all temporarely removed parts.

AAAMU-632. AFTER INSTALLATIONCAUTIONRefer to the separate manual "GENERAL INFORMATION / AFTER INSTALLATION" for details on what to do afterinstallation. (Document code: AOAMU-02A / Document part number: 988963-3480)2-1 CHARGING REFRIGERANT (HFC-134a)For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION / AFTERINSTALLATION" (pages 12-14, 20). 50STANDARD AMOUNT OF REFRIGERANT450 - 0 gramsCAUTIONEnsure to fill the refrigerant to the specified amount.- 17 -

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123456789101112131415161718192021222324252627F/L AlternatorF/L mainBattery 12VIgnition S/WHeater main relayBlower motorBlower S/WRadiator fan motorFan relay No. 1Fan relay No. 2Fan relay No. 3A/C sub motorMedium pressure S/WWater temperature S/WE/G ECUMg/CMg/C relayDimmer circuitPressure S/WVoltage regulatorSlip rateTemperatureLowHighCompressor rev. sensorThermistor RTHIgniter3. A/C AMPLIFIERAAAMU-63- 19 -

AAAMU-634. WIRING DIAGRAM891110121314151617181920- 20 -76

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