AIR CONDITIONING SYSTEM

Transcription

1 AIR CONDITIONING SYSTEM PRECAUTION CAUTION: AIR CONDITIONING SYSTEM Because the compressor has a highvoltage circuit, wear insulated gloves and pull out the service plug to cut the highvoltage circuit before inspection AE01 1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION AC2810 AC BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. (b) apply clean petroleum jelly to the skin. (c) go immediately to a hospital or see a physician for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT Wrong LO HI Okay LO HI N DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure valves are opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc Prius Preliminary Release (RM1075U) 740

2 552 AIR CONDITIONING SYSTEM 9. NOTICE FOR INITIALIZATION: (a) When disconnecting the negative () battery terminal, initialize the following systems after the terminal is reconnected. System Name see page Power Window Control System NOTICES FOR HYBRID SYSTEM ACTIVATION: When the warning lamp is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. With the power switch s power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. 11. PRECAUTIONS TO BE OBSERVED WHILE SERVIC- ING For the electric inverter compressor, use the ND OIL11. Electrical insulation performance may decrease significantly if even a small amount of oil other than ND OIL11 is used (or enters) in the refrigeration cycle, causing the DTC to be output. If other oil is accidentally used and a DTC is output, collect the compressor oil in the compressor and replace it with NDOIL11 to increase the NDOIL11 ratio amount. Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than NDOIL11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing the DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug clip before inspection, as some of the procedures require disconnecting the highvoltage connectors (see page ) Prius Preliminary Release (RM1075U) 741

3 AIR CONDITIONING SYSTEM 553 LOCATION 551AF01 Engine Room J/B PTC Heater Relay No.1 PTC Heater Relay No.2 Electric Inverter Compressor (w/motor Compressor Assy) Pressure Switch Heater Water Pump Assy Integration Relay Fusible Link Block Assy (HTR 40 A) A/C Ambient Temperature Sensor A/C Inverter (w/converter Inverter Assy) Engine Room J/B Integration Relay Fusible Link Block Assy (HTR 40 A) PTC HTR1 Fuse (30 A) *1 PTC HTR2 Fuse (30 A) *1 *1: Cold Area Models I Prius Preliminary Release (RM1075U) 742

4 554 AIR CONDITIONING SYSTEM Spiral Cable Steering Pad Switch RH Gateway ECU Steering Pad Switch LH Combination Meter Multi Display A/C Solar Sensor Hybrid Vehicle Control ECU Driver Side J/B Heater Relay A/C Fuse (10 A) GAUGE Fuse (10 A) ECUB Fuse (15 A) Body ECU DLC3 ECM A/C Room Temperature Sensor (Built in A/C Room Humidity Sensor) A/C Control Assembly I Prius Preliminary Release (RM1075U) 743

5 AIR CONDITIONING SYSTEM 555 Cooler Expansion Valve A/C Evaporator Temperature Sensor Cooler Evaporator No.1 Air Inlet Control Servomotor Air Outlet Control Servomotor Blower Assy PTC Heater *1 Heater Radiator Unit Assy Blower w/ Fan Motor Subassy Air Conditioning Radiator Assy Air Mix Control Servomotor *1: Cold Area Models I Prius Preliminary Release (RM1075U) 744

6 556 REFRIGERANT REFRIGERANT ONVEHICLE INSPECTION 5519C01 Sight Glass 1. INSPECT REFRIGERANT VOLUME (a) Check the sight glass of the cooler unit refrigerant liquid pipe E. (1) Set the vehicle according to the conditions below. Item All Doors Temperature setting Blower Speed A/C Condition Fully open MAX COLD HI ON (2) Check the sight glass under these conditions. I38559 Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* 2 No bubbles exist (DTC 76 is output) Empty, insufficient or excessive Refer to 3 and No temperature difference between compressor inlet and outlet Considerable temperature difference between compressor inlet and outlet Immediately after air conditioning is turned off, refrigerant remains clear Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Empty or nearly empty Proper or excessive Refer to 5 and 6 Excessive (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear (1) Discharge refrigerant (2) Remove air and supply proper amount of purified refrigerant Proper *: Bubbles in the sight glass with room temperature higher than usual can be considered normal if cooling is sufficient Prius Preliminary Release (RM1075U) 745

7 REFRIGERANT INSPECT REFRIGERANT PRESSURE WITH MAN- IFOLD GAUGE SET (a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Test conditions: Temperature at the air inlet with the switch set at RECIRC is 30 to 35 C (86 to 95 F) Blower speed control switch at HI position Temperature control switch at MAX COOLD position A/C switch ON Fully open doors (1) The refrigeration system functions normally Gauge reading: Low pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm 2 ) High pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm 2) (2) Moisture present in refrigeration system E50573 Condition: Periodically cools and then fails to cool I22117 Symptom Probable cause Diagnosis Corrective Actions During operation, pressure on low pressure side cycles between normal and vacuum Moisture in refrigerating system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. Cooler dryer in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant (1) Replace cooler dryer (2) Remove moisture in cycle by repeatedly evacuating air (3) Supply proper amount of new refrigerant 2004 Prius Preliminary Release (RM1075U) 746

8 558 REFRIGERANT Condition: Cooling system does not function effectively. (3) Insufficient cooling I22118 Symptom Probable cause Diagnosis Corrective Actions (1) Check for gas leakage and repair if necessary Pressure is low on both low and (2) Supply proper amount of new high pressure sides Bubbles are continuously seen through sight glass Gas leakage in refrigeration system Insufficient refrigerant Refrigerant leaking refrigerant (3) If the indicated pressure value is close to 0 when connected to Insufficient cooling performance the gauge, create a vacuum after inspecting and repairing location of leakage Condition: Cooling system does not function effectively. (4) Poor circulation of refrigerant I22119 Symptom Probable cause Diagnosis Corrective Action Pressure is low on both low and high pressure sides Frost exists on pipe from cooler Refrigerant flow is obstructed by dirt in cooler condenser core Cooler condenser core is clogged Replace cooler condenser core condenser to A/C unit 2004 Prius Preliminary Release (RM1075U) 747

9 559 REFRIGERANT (5) Refrigerant does not circulate Condition: Cooling system does not function (sometimes it may function). I22120 Symptom Probable cause Diagnosis Corrective Actions (1) Check cooler expansion valve Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side Frost or condensation is seen on piping on both sides of cooler condenser core or expansion valve Refrigerant flow is obstructed by moisture or dirt in refrigeration system Refrigerant flow obstructed by gas leaked from cooler expansion valve Refrigerant does not circulate (2) Clean out dirt in cooler expansion valve by blowing air (3) Replace cooler condenser core (4) Evacuate and charge new refrigerant (5) For gas leakage from cooler expansion valve, replace cooler expansion valve Condition: Cooling system does not function effectively. (6) Refrigerant overcharged or insufficient cooling of condenser I22121 Symptom Probable cause Diagnosis Correcyive Actions (1) Clean cooler condenser core Pressure is too high on both low Excessive refrigerant in fin and high pressure sides Excessive refrigerant cycle excessive refrigerant is (2) Check cooling fan with con- No air bubbles are seen through Insufficient cooling of cooler con- supplied denser fan motor operation the sight glass when compressor denser core Insufficienr cooling of cooler con- (3) If (1) and (2) are normal, check speed decreases denser core amount of refrigerant and supply proper amount of refrigerant 2004 Prius Preliminary Release (RM1075U) 748

10 5510 REFRIGERANT (7) Air present in refrigeration system Condition: Cooling system does not function. NOTE : These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. I22122 Symptom Probable cause Diagnosis Corrective Actions Pressure is too high on both low and high pressure sides Low pressure piping is too hot to touch Bubbles are seen through sight Air in system Air present in refrigeration system Insufficient vacuum purging (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate and charge new refrigerant glass (8) Expansion valve malfunction Condition: Insufficient cooling I22123 Symptom Probable cause Diagnosis Corrective Action Pressure is too high on both low and high pressure sides Frost or large amount of condensation on piping on low pressure side Trouble in cooler expansion valve Excessive refrigerant in low pressure piping Cooler expansion valve is opened too wide Replace cooler expansion valve 2004 Prius Preliminary Release (RM1075U) 749

11 REFRIGERANT 5511 (9) Defective compression compressor Condition: Insufficient cooling I22124 Symptom Probable cause Diagnosis Corrective Action Pressure is too high on both low and high pressure sides Pressure is too low on high pressure side Internal leak in cooler compressor Compression failure Leakage from damaged valve or sliding parts are broken Repair or replace cooler compressor Gauge readings (Reference) Pressure on low pressure side MPa (kgf/cm 2 ) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.9) 0.3 (3.0) 0.2 (2.0) 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) Blower LO Zone 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) Pressure on high pressure side MPa (kgf/cm 2 ) I Prius Preliminary Release (RM1075U) 750

12 5512 REPLACEMENT REFRIGERANT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (a) Turn the A/C switch on. (b) Operate the A/C with the setting temperature at 25 C (77 F) and the blower level at LO for 10 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. (c) Stop the engine. (d) Using SST, let the refrigerant gas out. SST ( , , , , , ) 2. CHARGE REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC134a (R134a). Standard: g ( oz.) SST ( , , , , , , , ) 5519D01 Amount to be charged Charge 100 g (3.53 oz.) Mean value in proper range High Pressure 30 g ( 1.1 oz.) Point where bubbles disappear Overcharged Subcool system Refrigerant Amount I30082 Do not turn the A/C on before charging with refrigerant as the cooler compressor doesn t work properly without any refrigerant, which causes the compressor to overheat. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass. HINT: Prepare a service can to recharge the refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90 %. 3. WARM UP COMPRESSOR (a) Turn the A/C switch on continuously for at least 1 minute to warm up the compressor. Be sure to warm up compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor Prius Preliminary Release (RM1075U) 751

13 REFRIGERANT INSPECT LEAKAGE OF REFRIGERANT (a) After recharging the refrigerant gas, inspect leakage of refrigerant gas using a halogen leak detector. (b) Perform in these conditions: Power switch off. Secure good ventilation (the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas). Repeat the test 2 or 3 times. Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is off: approx. 392 to 588 kpa (4 to 6 kgf/cm 2, 57 to 85 psi) Drain Hose Gas Leak Detector N14519 (c) Bring the gas leak detector close to the drain hose with the detector s power off. HINT: After the blower motor has stopped, leave the cooling unit for more than 15 minutes. Expose the gas leak detector sensor under the drain hose. When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (d) If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. (e) Disconnect the connector and leave the pressure switch for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test Prius Preliminary Release (RM1075U) 752

14 5514 REFRIGERANT LINE REFRIGERANT LINE COMPONENTS 5519E01 Cooler Refrigerant Liquid Pipe E (To Cooler Unit) Piping Clamp (Quick Joint) Suction Hose Subassy Discharge Hose Subassy 5.4 (55, 49 in. lbf) 9.8 (100, 87 in. lbf) 9.8 (100, 87 in. lbf) Electric Inverter Compressor Assy Condenser assy (w/ Receiver) (w/ Receiver Condenser Assy) I38552 N m (kgf cm, ft lbf) : Specified torque I Prius Preliminary Release (RM1075U) 753

15 AIR CONDITIONING RADIATOR ASSY COMPONENTS AIR CONDITIONING RADIATOR ASSY F01 Defroster Nozzle Assy Side Defroster Nozzle Duct No.1 Heater to Register Duct No.3 Side Defroster Nozzle Duct No.3 Heater To Register Duct No.2 Heater to Register Duct No.1 Piping Clamp (Quick Joint) Suction Hose Subassy Cooler Refrigerant Liquid Pipe E (To Cooler Unit) Piping Clamp(Quick Joint) Oring Oring Instrument Panel Brace Subassy No.1 Air Conditioning Unit Assy Blower Assy Compressor Oil NDOIL 11 or equivalent Nonreusable part : Use repair screws (parts No ) if the screws removed before cannot be tightened. Air Duct Rear No.3 I Prius Preliminary Release (RM1075U) 754

16 5516 AIR CONDITIONING RADIATOR ASSY Piping Clamp Piping Clamp Defroster Nozzle Assy LWR Heater Radiator Unit Subassy Air Conditioning Tube & Accessory Assy Expansion Valve Cover Cooler Evaporator Subassy No.1 Cooler Expansion Valve Oring Air Outlet Damper Servomotor Oring 3.5 (35, 30 in. lbf) Air Mix Control Servomotor Heater Piping Cover Evaporator Temperature Sensor (Cooler Thermistor No.1) Aspirator Pipe Quick Heater Assy Air Conditioning Amplifier Assy Air Duct No.1 N m (kgf cm, ft lbf) : Specified torque Compressor Oil NDOIL 11 or equivalent Nonreusable part I Prius Preliminary Release (RM1075U) 755

17 OVERHAUL AIR CONDITIONING RADIATOR ASSY 5517 HINT: Installation is in the reverse order of removal. COMPONENTS for instrument panel safety pad: See page 711. COMPONENTS for air conditioner radiator assy: See page DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 5512) SST ( , , , , , ) 5519G01 2. DISCONNECT SUCTION HOSE SUBASSY (a) Check the SST installation direction. SST HINT: Set the SST so that the stopper side is on the piping clamp lock side. (b) Install the SST on the piping clamp. I03838 Push SST Release Lever Pull I03839 (c) Push down on the SST with your thumb while holding the pipe with both hands. Be careful not to bend the pipe. (d) Pull the SST until the stopper touches the pipe. (e) Raise the SST stopper and remove the piping clamp with the SST from the pipe. (f) Remove the piping clamp from the SST. Disconnect the tube using hand Screw Driver (g) Disconnect the suction hose. (h) Remove the 2 Orings from the suction hose. Do not apply excessive force to the suction hose. Seal the opening of the disconnected part using vinyl tape to prevent moisture and foreign matter from entering. I DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) SST HINT: Disconnect the cooler refrigerant liquid pipe E following the same procedures as for the suction hose Prius Preliminary Release (RM1075U) 756

18 5518 AIR CONDITIONING RADIATOR ASSY 4. DISCONNECT HEATER WATER HOSE B Heater Water Hose B (a) Slide the clip and disconnect the heater water hose B. Heater Water Hose A Do not apply excessive force to the water hose B. Prepare a drain pan or cloth for when the cooling water leaks. 5. DISCONNECT HEATER WATER HOSE A (a) Slide the clip and disconnect the heater water hose A. I38565 Do not apply excessive force to the water hose A. Prepare a drain pan or cloth for when the cooling water leaks. 6. REMOVE INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) HINT: Refer to the removal procedures for the instrument panel with the passenger airbag assy. 7. REMOVE INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) HINT: Refer to the removal procedures for the instrument panel lower. 8. REMOVE AIR DUCT REAR NO.3 (a) Fold back the floor carpet. HINT: Fold back the floor carpet so that the air duct rear No.3 can be removed. (b) Disengage the 10 claws and then remove the air duct rear No Claws I REMOVE HEATER TO REGISTER DUCT NO.3 (a) Remove the clip and then the heater to register duct No.3 with the side defroster nozzle duct No.2. I REMOVE HEATER TO REGISTER DUCT NO.1 (a) Remove the heater to register duct No.1 with the side defroster nozzle duct No.1. I Prius Preliminary Release (RM1075U) 757

19 AIR CONDITIONING RADIATOR ASSY REMOVE HEATER TO REGISTER DUCT NO.2 (a) Remove the heater to register duct No.2. I REMOVE DEFROSTER NOZZLE ASSY (a) Remove the 2 clips. (b) Disengage the 3 claws and then remove the defroster nozzle assy. 3 Claws I REMOVE TRANSMISSION CONTROL ECU ASSY 14. REMOVE ECM (SEE PAGE 1024) 15. REMOVE NETWORK GATEWAY ECU (SEE PAGE 6726) 16. REMOVE INSTRUMENT PANEL BRACE SUBASSY NO.1 (a) Remove the clamp and disconnect the harness. (b) Remove the 2 bolts and the nut and then the instrument panel brace subassy No.1. I REMOVE AIR CONDITIONING AMPLIFIER ASSY (SEE PAGE 5547) 18. REMOVE STEERING COLUMN ASSY (SEE PAGE 508) 2004 Prius Preliminary Release (RM1075U) 758

20 5520 AIR CONDITIONING RADIATOR ASSY 19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY (a) Disconnect each connector and remove each clamp. Disconnect the wire harness. 7 Clamps I38978 (b) Remove the 7 bolts and the 2 nuts and then the instrument panel reinforcement assy with the air conditioner unit assy. I Prius Preliminary Release (RM1075U) 759

21 AIR CONDITIONING RADIATOR ASSY REMOVE AIR CONDITIONER UNIT ASSY (a) Disconnect the 5 connectors and remove the 9 clamps. Disconnect the wire harness. 9 Clamps I38974 (b) Remove the bolt and the clamp and then disconnect the junction connector. Clamp I38975 (c) Remove the 2 screws and the air conditioner unit assy from the instrument panel reinforcement assy. I REMOVE BLOWER ASSY (a) Remove the 2 screws. (b) Disengage the fittings with the air conditioner assy and then remove the blower assy. I Prius Preliminary Release (RM1075U) 760

22 5522 AIR CONDITIONING RADIATOR ASSY 22. REMOVE DEFROSTER NOZZLE ASSY LWR (a) Disengage the 2 claws and then remove the defroster lower nozzle assy. 2 Claws I REMOVE AIR MIX CONTROL SERVOMOTER (a) Remove the 2 screws and then the airmix control servomotor. I AIR OUTLET CONTROL SERVOMOTER (a) Remove the 2 screws and disengage the claw. (b) Remove the air outlet control servomoter. Claw I REMOVE AIR CONDITIONING TUBE & ACCESSORY ASSY (a) Remove the 2 screws and then the expansion valve cover. I38826 (b) Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts. (c) Remove the air conditioner tube assy. (d) Remove the 2 Orings from the air conditioner tube assy. I Prius Preliminary Release (RM1075U) 761

23 AIR CONDITIONING RADIATOR ASSY REMOVE COOLER EXPANSION VALVE (a) Remove the cooler expansion valve from the cooler evaporator No.1. I REMOVE HEATER RADIATOR UNIT SUBASSY (a) Remove the clamp and then disconnect the evaporator temperature sensor connector. (b) Remove the clamp and disengage the 2 claws. Remove the heater piping cover. 2 Clamps 2 Claws I39537 (c) Remove the 4 screws and the 4 clamps. (d) Remove the radiator heater unit from the air conditioner radiator assy. Prepare a drain pan or cloth for when the cooling water leaks. I REMOVE AIR DUCT NO.1 (a) Remove the 2 screws and then the air duct No.1. E70849 I Prius Preliminary Release (RM1075U) 762

24 5524 AIR CONDITIONING RADIATOR ASSY 29. REMOVE QUICK HEATER ASSY (a) Remove the 4 screws and then the quick heater assy. I REMOVE COOLER EVAPORATOR SUBASSY NO.1 (a) Remove the 7 screws and then the cooler evaporator No.1 from the heater case. I38832 (b) Remove the 2 Orings from the cooler evaporator No.1. E REMOVE EVAPORATOR TEMPERAURE SENSOR (a) Disengage the 2 claws and then remove the evaporator temperature sensor. : 2 Claws I INSTALL COOLER EVAPORATOR SUBASSY NO.1 (a) Sufficiently apply compressor oil (NDOIL11) to 2 new O rings and fitting surface. Install the 2 Orings to the cooler evaporator No.1. Compressor oil: NDOIL 11 or equivalent E Prius Preliminary Release (RM1075U) 763

25 AIR CONDITIONING RADIATOR ASSY 5525 Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the cooler evaporator No.1 with the 7 screws. I INSTALL COOLER EXPANSION VALVE (a) Install the cooler expansion valve to the cooler evaporator No.1. I38828 I INSTALL AIR CONDITIONING TUBE & ACCESSORY ASSY (a) Sufficiently apply compressor oil (NDOIL11) to 2 new O rings and fitting surface. Install the 2 Orings to the conditioner tube assy. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the air conditioner tube assy to the cooler evaporator No.1, placing the cooler expansion valve between them, Using a hexagon wrench 4 mm (0.16 in.), install the 2 hexagon bolts. Torque: 3.5 N m (35 kgf cm, 30 in. lbf) 2004 Prius Preliminary Release (RM1075U) 764

26 5526 AIR CONDITIONING RADIATOR ASSY (c) Install the expansion cover with the 2 screws. I INSTALL AIR CONDITIONER UNIT ASSY (a) Install the air conditioner unit assy to the instrumentpanel reinforcement assy with the 2 screws. HINT: Use repair screws (parts No ) if the screws removed before cannot be tightened. I38976 (b) Connect the junction connector with the bolt and the clamp. Clamp I38975 (c) Install the instrument panel wire harness with the 5 connectors and the 9 clamps. 9 Clamps I Prius Preliminary Release (RM1075U) 765

27 AIR CONDITIONING RADIATOR ASSY INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY (a) Install the instrument panel reinforcement assy with the 7 bolts. (b) Install the 2 nuts to the air conditioner unit assy and temporarily tighten them. I INSTALL INSTRUMENT PANEL BRACE SUBASSY NO.1 (a) Install the instrument panel brace subassy No.1 with the 2 bolts and nut. (b) Install the harness with a clamp. I FULLY TIGHTEN AIR CONDITIONER UNIT ASSY (a) Fully tighten the air conditioner unit assy with the 2 nuts. Tighten the nuts in the order indicated in the illustration. (1) (2) I INSTALL STEERING COLUMN ASSY (SEE PAGE 508) 40. INSTALL INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) HINT: Refer to the installation procedures for the instrument panel subassy lower. 41. INSTALL INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assy Prius Preliminary Release (RM1075U) 766

28 5528 AIR CONDITIONING RADIATOR ASSY 42. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) Connect Wrong Gap (a) Remove the attached vinyl tape from the pipe disconnected part. (b) Sufficiently apply compressor oil (NDOIL11) to 2 new O rings and pipe connecting part. Do not use any compressor oil other than NDOIL11 I06878 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (c) Install the Orings to the pipe. (d) Insert the pipe joint into the cooler unit fitting hole securely. (e) Using the piping clamp, install the cooler unit refrigerant liquid pipe E. Ensure that the piping clamp is securely engaged. 43. INSTALL SUCTION HOSE SUBASSY HINT: Install the suction hose subassy following the same procedures as for the cooler unit refrigerant liquid pipe E. 44. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 45. ADD ENGINE COOLANT (SEE PAGE 1611) 46. CHARGE REFRIGERANT (SEE PAGE 5512) SST ( , , , , , , , ) Specified amount: g ( oz.) 47. CHECK FOR ENGINE COOLANT LEAKS (SEE PAGE 1611) 48. WARM UP COMPRESSOR (SEE PAGE 5512) 49. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 50. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (SEE PAGE ) 2004 Prius Preliminary Release (RM1075U) 767

29 BLOWER ASSY 5529 BLOWER ASSY COMPONENTS 5519H01 Blower Assy Air Duct Subassy Air Inlet Servomotor Clean Air Filter Blower Motor Control Blower w/ Fan Motor Subassy Air Filter Cover Plate Cooler Wiring Harness Subassy No.2 Blower Motor Cover : Use repair screw (parts No ) if the screw removed before cannot be tightened. I Prius Preliminary Release (RM1075U) 768

30 5530 OVERHAUL BLOWER ASSY HINT: Installation is in the reverse order of removal. COMPONENTS for instrument panel safety pad: See page 711. COMPONENTS for blower assy: See page REMOVE INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) 2. REMOVE INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) 3. REMOVE TRANSMISSION CONTROL ECU ASSY 4. REMOVE ECM (SEE PAGE 1024) 5. REMOVE NETWORK GATEWAY ECU (SEE PAGE 6726) 6. REMOVE HEATER TO REGISTER DUCT NO.1 (SEE PAGE 5517) 5519I01 7. REMOVE AIR DUCT SUBASSY (a) Remove the 2 screws and then the air duct subassy. I REMOVE BLOWER ASSY (a) Disconnect the 10 connectors and remove the 5 clamps. (b) Disconnect the wire harness. 5 Clamps I Prius Preliminary Release (RM1075U) 769

31 BLOWER ASSY 5531 (c) Remove the 3 screws the nut and then the blower assy. I REMOVE AIR INLET SERVOMOTER (a) Remove the 3 screws and then the air inlet servomoter. I REMOVE BLOWER MOTOR CONTROL (a) Disconnect the connector and remove the 2 screws. (b) Remove the blower motor control. I REMOVE COOLER WIRING HARNESS SUBASSY NO.2 (a) Remove the 5 screws and then the blower motor cover. I38845 (b) Remove the cooler wiring harness subassy No.2 from the blower w/fan motor subassy. I Prius Preliminary Release (RM1075U) 770

32 5532 BLOWER ASSY 12. REMOVE BLOWER W/FAN MOTOR SUBASSY (a) Remove the 3 screws and then the blower w/fan motor subassy. I REMOVE CLEAN AIR FILTER (a) Disengage the 2 claws and then remove the air filter cover plate with the clean air filter. (b) Remove the clean air filter from the air filter cover plate. 2 Claws I INSTALL BLOWER ASSY (a) Install the blower assy with the 3 screws HINT: Use repair screw (parts No ) if the screw (A) removed before cannot be tightened. (A) I38841 (b) Install the wire harness with the 10 connectors and 5 clamps. (c) Install the transponder key computer assy connector. 5 Clamps I INSTALL INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) HINT: Refer to the installation procedures for the instrument panel subassy lower Prius Preliminary Release (RM1075U) 771

33 BLOWER ASSY INSTALL INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assy Prius Preliminary Release (RM1075U) 772

34 5534 ELECTRIC INVERTER COMPRESSOR ASSY ELECTRIC INVERTER COMPRESSOR ASSY REPLACEMENT 1. REMOVE REAR FLOOR BOARD NO.2(SEE PAGE 21116) 2. REMOVE DECK FLOOR BOX REAR(SEE PAGE 21116) 3. REMOVE REAR FLOOR BOARD NO.3(SEE PAGE 21116) 4. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE601) 5. REMOVE SERVICE PLUG GRIP(SEE PAGE 21116) 6. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM SST ( , , , , , ) 5519J01 I DISCONNECT DISCHARGE HOSE SUBASSY (a) Remove the bolt and disconnect the discharge hose sub assy. (b) Remove the Oring from the discharge hose subassy. Seal the openings of the disconnected parts of the discharge hose and the compressor assy with the electric inverter compressor assy using vinyl tape to prevent moisture and foreign matter from entering. I DISCONNECT SUCTION HOSE SUBASSY (a) Remove the bolt and disconnect the suction hose sub assy. (b) Remove the Oring from the suction hose subaasy. Seal the openings of the disconnected parts of the suction hose and the compressor assy with the electric inverter compressor assy using vinyl tape to prevent moisture and foreign matter from entering. (1) (2) 9. REMOVE ELECTRIC INVERTER COMPRESSOR ASSY (a) Release the greencolored lock.(1) (b) Disconnect the connector.(2) (c) Remove the 3 clamps and disconnect the wire harness. Wear insulated gloves when performing the procedures. Insulate the connector by sealing it with tape. :3 Clamps I Prius Preliminary Release (RM1075U) 773

35 ELECTRIC INVERTER COMPRESSOR ASSY 5535 (d) Remove the 3 bolts and then the electric inverter compressor assy. I38563 Service Valve Service Valve I INSPECT COMPRESSOR OIL (a) Gradually discharge inert gas (helium) from the service valve when replacing the electric inverter compressor assy with the inverter compressor assy with a new one. Drain the following amount of oil from the new electric inverter compressor before installation. Standard: (Oil capacity inside new electric inverter compressor 100 (+ 15 ml)) (Remaining oil amount in the removed compressor assy with the motor (w/ motor compressor assy)) = (Oil amount to be removed before installation) Observe the precautions on the cooler removal/ installation procedures when checking the amount of compressor oil. Because compressor oil remains in the pipes of the vehicle, if a new cooler compressor assy is installed without removing the oil inside, the amount of oil becomes too great, preventing heat exchange in the refrigerant cycles and causing refrigerant failure and/or abnormal vibration. Check for oil leakage if the remaining oil amount in the removed compressor is too low. If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (1) (2) 11. TEMPORARILY TIGHTEN ELECTRIC INVERTER COMPRESSOR ASSY (a) Temporarily tighten the electric inverter compressor assy with the 2 bolts. Tighten them in the order indicated in the illustration. E Prius Preliminary Release (RM1075U) 774

36 5536 ELECTRIC INVERTER COMPRESSOR ASSY (1) 12. FULLY TIGHTEN ELECTRIC INVERTER COMPRESSOR ASSY (a) Fully tighten the electric inverter compressor assy with the 2 bolts. Torque: 25 N m (255 kgf cm, 18 ft lbf) Tighten them in the order indicated in the illustration. I38564 (2) I41159 (b) Fully tighten the electric inverter compressor assy with the bolt. Torque: 25 N m (255 kgf cm, 18 ft lbf) I38564 I41160 (2) (1) (c) Connect the wire harness. Wear insulated gloves when performing the procedures. (1) Connect the wire harness 3 clamps. (2) Connect the connector.(1) (3) Lock the greencolored lock.(2) I Clamps I41121 I INSTALL SUCTION HOSE SUBASSY (a) Sufficiently apply compressor oil to a new Oring and fitting surface of the electric inverter compressor assy. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the Oring to the suction hose subassy. (c) Install the suction hose subassy with the bolt. Torque: 9.8 N m (100 kgf cm, 87 in. lbf) 2004 Prius Preliminary Release (RM1075U) 775

37 ELECTRIC INVERTER COMPRESSOR ASSY INSTALL DISCHARGE HOSE SUBASSY (a) Sufficiently apply compressor oil to a new Oring and fitting surface of the electric inverter compressor assy. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, I38560 compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the Oring to the discharge hose. (c) Install the discharge hose with the bolt. Torque: 9.8 N m (100 kgf cm, 87 in. lbf) 15. INSTALL SERVICE PLUG GRIP(SEE PAGE 21116) 16. CONNECT BATTERY NEGATIVE TERMINAL 17. INSTALL REAR FLOOR BOARD NO INSTALL DECK FLOOR BOX REAR 19. INSTALL REAR FLOOR BOARD NO CHARGE REFRIGERANT (SEE PAGE 5512) SST ( , , , , , , , ) Specified amount: g ( oz.) 21. WARM UP COMPRESSOR (SEE PAGE 5512) 22. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 2004 Prius Preliminary Release (RM1075U) 776

38 5538 W/RECEIVER CONDENSER ASSY ONVEHICLE INSPECTION W/RECEIVER CONDENSER ASSY 1. INSPECT COOLER CONDENSER CORE (a) If the fins of the condenser assy (w/ receiver) are dirty, clean them with water and dry them with compressed air. Do not damage the fins of the cooler condenser core. (b) If the fins of the condenser assy (w/ receiver) are bent, straighten them using a screwdriver or pliers. 2. INSPECT LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check the pipe joints for gas leakage. (b) Check the tightening torque of the joint if gas leakage is detected in a pipe joint. 5519K Prius Preliminary Release (RM1075U) 777

39 W/RECEIVER CONDENSER ASSY 5539 COMPONENTS 5519L01 Inverter Bracket No.1 Radiator Support Upper Suction Bracket 7.5 (76, 66 in. lbf) Hood Lock Assy 5.0 (51, 44 in. lbf) 5.0 (51, 44 in. lbf) Radiator Support Subassy Upper LH 7.5 (76, 66 in. lbf) Radiator Support Subassy Upper RH Angle Discharge Hose Subassy 5.4 (55, 49 in. lbf) 3.9 (40, 35 in. lbf) 3.9 (40, 35 in. lbf) Angle Condenser Assy (w/ Receiver) (w/ Receiver Condenser Assy) 3.9 (40, 35 in. lbf) Cooler Refrigerant Liquid Pipe E (To Cooler Unit) 3.9 (40, 35 in. lbf) 5.4 (55, 49 in. lbf) Cooler Dryer Oring Cap 2.9 (30, 25 in.lbf) Compressor Oil NDOIL 11 or equivalent Nonreusable part N m (kgf cm, ft lbf) : Specified torque I Prius Preliminary Release (RM1075U) 778

40 5540 W/RECEIVER CONDENSER ASSY 5519M01 OVERHAUL HINT: COMPONENTS for condenser assy: See page DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 5512) SST ( , , , , , ) 2. REMOVE FRONT FENDER LINER LH 3. REMOVE FRONT FENDER LINER RH 4. REMOVE FRONT BUMPER COVER 5. REMOVE INVERTER BRACKET NO.1 (SEE PAGE 1633) I DISCONNECT DISCHARGE HOSE SUBASSY (a) Remove the bolt and disconnect the discharge hose sub assy from the condenser assy (w/ receiver). (b) Remove the Oring from the discharge hose subassy. Seal the openings of the disconnected parts of the discharge hose and the condenser assy using vinyl tape to prevent moisture and foreign matter from entering. I DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the bolt and disconnect the cooler unit refrigerant liquid pipe E from the condenser assy (w/ receiver). (b) Remove the Oring from the cooler refrigerant liquid pipe E. Seal the openings of the disconnected parts of the cooler unit refrigerant liquid pipe E and the condenser assy using vinyl tape to prevent moisture and foreign matter from entering. 8. REMOVE RADIATOR SUPPORT SUBASSY UPPER RH (a) Remove the 4 bolts and then the radiator support sub assy upper RH. I Prius Preliminary Release (RM1075U) 779

41 W/RECEIVER CONDENSER ASSY REMOVE RADIATOR SUPPORT SUBASSY UPPER LH (a) Remove the 4 bolts and then the radiator support sub assy upper LH. I REMOVE W/RECEIVER CONDENSER ASSY (a) Remove the 2 angles. I38557 (b) Remove the 2 bolts and then the condenser assy (w/ receiver). I REMOVE COOLER DRYER (a) Using the straight hexagon wrench 14mm (0.55 in.), remove the cap from the modulator. 14 mm (0.55 in.) Hexagon Wrench Modulator I32993 (b) Remove the Oring from the cap. E55408 I Prius Preliminary Release (RM1075U) 780

42 5542 W/RECEIVER CONDENSER ASSY (c) Using pliers, remove the cooler dryer. I INSTALL COOLER DRYER (a) Using pliers, install the cooler dryer to the modulator. (b) Install a new Oring to the cap. I32994 E55408 (c) Sufficiently apply compressor oil (NDOIL11) to the O ring and cap fitting surface. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Using a straight hexagon wrench 14mm (0.55 in.), install the cap to the cooler condenser core. Torque: 2.9 N m (30 kgf cm, 25 in. lbf) 14 mm (0.55 in.) Hexagon Wrench Modulator I INSTALL W/RECEIVER CONDENSER ASSY (a) Install the condenser assy (w/ receiver) with 2 bolts. Torque: 3.9 N m (40 kgf cm, 35 in. lbf) I Prius Preliminary Release (RM1075U) 781

43 W/RECEIVER CONDENSER ASSY 5543 (b) Install the 2 angles to the condenser assy (w/ receiver). I38557 (A) (C) (A) (B) I INSTALL RADIATOR SUPPORT SUBASSY UPPER RH (a) Install the radiator support subassy upper RH with the 4 bolts. Torque: Bolt A: 5.0 N m (51 kgf cm, 44 in. lbf) Bolt B: 3.9 N m (40 kgf cm, 35 in. lbf) Bolt C: 7.5 N m (76 kgf cm, 66 in. lbf) (A) (C) (A) (B) I INSTALL RADIATOR SUPPORT SUBASSY UPPER LH (a) Install the radiator support subassy upper LH with the 4 bolts. Torque: Bolt A: 5.0 N m (51 kgf cm, 44 in. lbf) Bolt B: 3.9 N m (40 kgf cm, 35 in. lbf) Bolt C: 7.5 N m (76 kgf cm, 66 in. lbf) 16. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the attached vinyl tape from the disconnected parts of the cooler refrigerant liquid pipe E and condenser assy (w/ receiver). (b) Install a new Oring to the cooler refrigerant liquid pipe E. (c) Sufficiently apply compressor oil (NDOIL11) to the O ring and the cooler refrigerant liquid pipe E fitting surface. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power Prius Preliminary Release (RM1075U) 782

44 5544 W/RECEIVER CONDENSER ASSY I38555 (d) Install the cooler refrigerant liquid pipe E to the condenser assy (w/ receiver) with the bolt. Torque: 5.4 N m (55 kgf cm, 47 in. lbf) 17. INSTALL DISCHARGE HOSE SUBASSY (a) Remove the attached vinyl tape from the disconnected parts of the discharge hose subassy and the condenser assy (w/ receiver). (b) Install a new Oring to the discharge hose subassy. (c) Sufficiently apply compressor oil (NDOIL11) to the O ring and the discharge hose fitting surface. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Install the discharge hose to the condenser assy (w/ receiver) with the bolt. Torque: 5.4 N m (55 kgf cm, 47 in. lbf) I INSTALL INVERTER BRACKET NO.1 (SEE PAGE 1633) 19. INSTALL FRONT BUMPER COVER 20. INSTALL FRONT FENDER LINER RH 21. INSTALL FRONT FENDER LINER LH 22. CHARGE REFRIGERANT (SEE PAGE 5512) SST ( , , , , , , , ) Specified amount: g ( oz.) 23. WARM UP COMPRESSOR (SEE PAGE 5512) 24. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 2004 Prius Preliminary Release (RM1075U) 783

45 HEATER WATER PUMP ASSY REPLACEMENT HEATER WATER PUMP ASSY N01 1. DISCONNECT HEATER WATER HOSE C (a) Disengage the clip and disconnect the wire harness. Clip I38851 (b) Slide the hose clip and then disconnect the heater water hose C. Do not apply excessive force to the heater water hose C. Prepare a drain pan or cloth for when the cooling water leaks. I REMOVE HEATER WATER PUMP ASSY (a) Disconnect the connector. (b) Remove the 2 bolts and then disconnect the heater water pump assy. I38969 (c) Slide the hose clip and then disconnect the heater water hose A. (d) Remove the heater water pump assy. Do not apply excessive force to the heater water hose A. Prepare a drain pan or cloth for when the cooling water leaks. I Prius Preliminary Release (RM1075U) 784

46 5546 HEATER WATER PUMP ASSY L H Ditch 3. INSTALL HEATER WATER PUMP ASSY (a) Install the heater water hose A with the hose clip. Ensure that the hose ditch faces upwards. Install the hose clip in the direction as shown in the illustration. I38971 (b) Install the heater water pump assy with the 2 bolts. Tighten them in the order indicated in the illustration. (c) Connect the connector. I38969 WR H Pink 4. INSTALL HEATER WATER HOSE C (a) Install the heater water hose C with the hose clip. Install the hose marking facing upwards. Install the hose clip in the direction as shown in the illustration. I ADD ENGINE COOLANT (SEE PAGE 1611) 6. CHECK FOR ENGINE COOLANT LEAKS (SEE PAGE 1611) 2004 Prius Preliminary Release (RM1075U) 785

47 AIR CONDITIONING AMPLIFIER ASSY AIR CONDITIONING AMPLIFIER ASSY REPLACEMENT 1. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (SEE PAGE 7113) 2. REMOVE AIR DUCT REAR NO.3 (SEE PAGE 5517) O01 3. REMOVE AIR CONDITIONING AMPLIFIER ASSY (a) Disconnect the connector. (b) Remove the 2 screws and then the air conditioning amplifier assy. I Prius Preliminary Release (RM1075U) 786