AIR CONDITIONING -> Compressor and Magnetic Clutch for Your Toyota Avensis 4 Door First Generation (1997-2003)

AC–11  
AIR CONDITIONING  
COMPRESSORAND MAGNETIC CLUTCH  
COMPRESSOR AND MAGNETIC  
CLUTCH  
AC1GA–05  
ON–VEHICLE INSPECTION  
1.  
INSPECT COMPRESSOR FOR METALLIC SOUND  
Check there is abnormal metallic sound from the compressor  
when the A/C switch is ON.  
If abnormal metallic sound is heard, replace the compressoras-  
sembly.  
2.  
INSPECT REFRIGERANT PRESSURE (See page  
AC–1)  
3.  
INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-  
ANT  
Using a gas leak detector, check for leakage of refrigerant.  
If there is any leakage, replace the compressor assembly.  
4.  
INSPECT COMPRESSOR LOCK SENSOR RESIS-  
TANCE  
2
(a) Disconnect the connector.  
(b) Measure resistance between terminals 1 and 2 .  
Standard resistance:  
1
165 – 205 at 20 °C (68 °F)  
If resistance is not as specified, replace the sensor.  
5.  
6.  
7.  
CHECK FOR LEAKAGE OF GREASE FROM CLUTCH  
BEARING  
CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR  
ROTOR  
I12997  
INSPECT MAGNETIC CLUTCH BEARING FOR NOISE  
(a) Start engine.  
(b) Check for abnormal noise from the compressor when the  
A/C switch is OFF.  
If abnormal noise is being emitted, replace the magnetic clutch.  
8.  
INSPECT MAGNETIC CLUTCH OPERATION  
3
(a) Disconnect the connector.  
(b) Connect the positive (+) lead form the battery to terminal  
3 and the negative (–) lead to the body ground.  
(c) Check that the magnetic clutch energized.  
If operation is not as specified, replace the magnetic clutch.  
I12998  
AVENSIS/CORONA SUP (RM781E)  
AC–12  
AIR CONDITIONING  
COMPRESSORAND MAGNETIC CLUTCH  
AC1GB–03  
COMPONENTS  
Suction Hose  
1ZZ–FE, 3ZZ–FE Engines:  
10(100, 7)  
Compressor  
Discharge Hose  
z O–Ring  
25 (250, 18)  
Drive Belt  
Engine Under Cover RH  
x 5  
10(100, 7)  
1AZ–FSE Engine:  
Suction Hose  
Discharge Hose  
z O–Ring  
z O–Ring  
Compressor  
25 (250, 18)  
Drive Belt  
25 (250, 18)  
x 5  
N·m (kgf·cm, ft·lbf) : Specified torque  
Engine Under Cover RH  
z Non–reusable part  
I18811  
AVENSIS/CORONA SUP (RM781E)  
AC–13  
AIR CONDITIONING  
COMPRESSORAND MAGNETIC CLUTCH  
AC2IP–02  
REMOVAL  
1.  
RUN ENGINE AT IDLE SPEED WITH A/C ON FOR  
APPROX. 10 MINUTES  
2.  
3.  
STOP ENGINE  
DISCONNECT NEGATIVE (–) TERMINAL CABLE  
FROM BATTERY  
4.  
DISCHARGE REFRIGERANT FROM REFRIGERATION  
SYSTEM  
5.  
6.  
REMOVE ENGINE UNDER COVER RH  
REMOVE DRIVE BELT (See page AC–3)  
7.  
DISCONNECT DISCHARGE AND SUCTION HOSES  
Remove the 2 bolts and disconnect the both hoses.  
NOTICE:  
Cap the open fittings immediately to keep moisture or dirt  
out of the system.  
I12999  
8.  
1ZZ–FE, 3ZZ–FE Engines:  
REMOVE COMPRESSOR  
(a) Disconnect the connector.  
(b) Disconnect the wire harness clamp.  
(c) Remove the 3 bolts and compressor.  
I13000  
9.  
1AZ–FSE Engine:  
REMOVE COMPRESSOR  
(a) Disconnect the connector.  
(b) Disconnect the wire harness clamp.  
(c) Remove the 4 bolts and compressor.  
AVENSIS/CORONA SUP (RM781E)  
AC–14  
AIR CONDITIONING  
COMPRESSORAND MAGNETIC CLUTCH  
AC39H–01  
INSTALLATION  
1.  
1ZZ–FE, 3ZZ–FE Engines:  
INSTALL COMPRESSOR  
(a) Install the compressor with 3 bolts.  
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)  
(b) Connect the connector.  
I13000  
2.  
1AZ–FSE Engine:  
INSTALL COMPRESSOR  
(a) Install the compressor with 4 bolts.  
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)  
(b) Connect the connector.  
3.  
CONNECT DISCHARGE AND SUCTION HOSES  
(a) Lubricate 2 new O–rings with compressor oil and install  
them to the hoses.  
(b) Connect the both hoses with 2 bolts.  
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)  
NOTICE:  
Hose should be connected immediately after the caps have  
been removed.  
I12999  
4.  
5.  
6.  
INSTALL AND CHECK DRIVE BELT (See page  
AC–2, AC–4)  
CONNECT NEGATIVE (–) TERMINAL CABLE TO BAT-  
TERY  
EVACUATE AIR FROM REFRIGERATION SYSTEM  
CHARGE SYSTEM WITH REFRIGERANT  
Specified amount: 460 ± 20 g (16.23 ± 0.71 oz.)  
INSPECT FOR LEAKAGE OF REFRIGERANT  
7.  
Using a gas leak detector, check for leakage of refrigerant.  
If there is leakage, check the tightening torque at the joints.  
8.  
INSPECT A/C OPERATION  
AVENSIS/CORONA SUP (RM781E)