Air Conditioning Radiator ASSY: Overhaul

HINT:

COMPONENTS: See INSTRUMENT PANEL/METER and COMPONENTS 

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE  REPLACEMENT  ) 

   SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

2. REMOVE FR WIPER ARM RH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
3. REMOVE FR WIPER ARM LH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
4. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
7. REMOVE WINDSHIELD WIPER LINK ASSY (SEE  WINDSHIELD WIPER MOTOR ASSY  ) 
8. REMOVE FRONT SHOCK ABSORBER CAP RH (W/AIR SUSPENSION) (SEE  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
9. REMOVE FRONT SHOCK ABSORBER CAP LH (W/AIR SUSPENSION) (SEE  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
10. REMOVE COWL TOP PANEL SUB-ASSY OUTER 
    1. Remove the clamp and disconnect the rubber grommet.
    2. Remove the 4 bolts, 6 nuts and cowl top panel sub-assy outer.
    Fig 1: Removing Bolts and Nuts, Cowl Top Panel Sub-Assy
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. DISCONNECT LIQUID TUBE SUB-ASSY A 
    1. Install SST(s) on piping clamp.

       SST 09870-00025

       HINT:

       Make sure the direction of the piping clamp claw and SST(s) by seeing the illustration shown on the caution label.

    2. Push down SST(s) and release the clamp lock.
       NOTE: Be careful not to deform the tube when pushing SST(s).
    3. Pull SST(s) slightly and push the release lever, and then remove the piping clamp with SST(s).
    Fig 2: Pulling SST(s) Slightly, Pushing Release Lever And Removing Piping Clamp With SST(s)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the liquid tube sub-assy A.
       NOTE:

       • Do not use tools like screwdriver to remove the tube.
       • Cap the open fittings immediately to keep moisture or dirt out of the system.
       Fig 3: Disconnecting Liquid Tube Sub-Assy A

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 O-rings from the liquid tube sub-assy A.
12. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO. 1 

    SST 09870-00015

    HINT:

    Disconnection of the cooler refrigerant suction hose No. 1 is same as the liquid tube sub-assy.

13. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip, and then disconnect the heater outlet water hose.
       NOTE:

       • Do not apply any excessive force to the heater outlet water hose.
       • Prepare a drain pan or cloth for when the cooling water leaks.
       Fig 4: Disconnecting Heater Outlet Water Hose

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. DISCONNECT HEATER INLET WATER HOSE 

    HINT:

    Disconnection of the heater water inlet hose is same as the heater outlet water hose.

15. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (SEE STEP 37 IN  REPLACEMENT  ) 

    HINT:

    Refer to the instructions for removal of the instrument panel safety pad sub-assy w/passenger air bag assy.

16. REMOVE ECM (SEE  ECM (3MZ-FE)  ) 
17. REMOVE AIR CONDITIONER AMPLIFIER ASSY (SEE  AIR CONDITIONER AMPLIFIER ASSY  ) 
18. REMOVE AIR DUCT REAR NO. 2 
    1. Take up the floor carpet.

       HINT:

       Take up the floor carpet so that the air duct rear No. 2 can be removed.

    2. Release the claw fitting and remove the air duct rear No. 2.
    Fig 5: Removing Air Duct Rear No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE AIR DUCT REAR NO. 1 
    1. Take up the floor carpet.

       HINT:

       Take up the floor carpet so that the air duct rear No. 1 can be removed.

    2. Release the claw fitting and remove the air duct rear No. 1.
    Fig 6: Removing Air Duct Rear No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE AIR DUCT NO. 1 
    1. Remove the bolt.
    2. Release the 3 claw fittings and remove the air duct No. 1.
    Fig 7: Removing Air Duct No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. SEPARATE TRANSMISSION CONTROL CABLE ASSY (SEE STEP 14  OVERHAUL  ) 
22. REMOVE SHIFT LEVER ASSY (SEE STEP 15  OVERHAUL  ) 
23. REMOVE INSTRUMENT PANEL BRACKET NO. 4 
    1. Remove the 4 nuts and instrument panel bracket No. 4.
       Fig 8: Removing Nuts And Instrument Panel Bracket No. 4

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 1 
    1. Remove the clamp and disconnect the connector.
    2. Remove the 3 bolts and 2 nuts and instrument panel brace sub-assy No. 1.
    Fig 9: Removing Bolts And Nuts, Instrument Panel Brace Sub-Assy No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 2 
    1. Remove the clamp and disconnect the connector.
    2. Remove the 3 bolts and 2 nuts and instrument panel brace sub-assy No. 2.
    Fig 10: Removing Bolts And Nuts, Instrument Panel Brace Sub-Assy No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY 

    MANUAL TILT: (see OVERHAUL )

    POWER TILT & TELESCOPIC: (see OVERHAUL )

27. REMOVE STEERING COLUMN ASSY 

    MANUAL TILT: (see OVERHAUL )

    POWER TILT & TELESCOPIC: (see OVERHAUL )

28. REMOVE AIR DUCT SUB-ASSY NO. 1 
    1. Remove the 3 nuts and air duct sub-assy No. 1.
       Fig 11: Removing Nuts And Air Duct Sub-Assy No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY 
    1. Remove the 4 bolts and 4 nuts.
       Fig 12: Removing Instrument Panel Reinforcement Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp.
    3. Disconnect the connectors.
    4. Remove the 9 bolts and the 2 nuts and then remove the instrument panel reinforcement while holding the air conditioner unit assy.

       HINT:

       Make sure to keep the air conditioner unit assy unmoved as the installation parts of the bracket in the air conditioner unit assy could be damaged.

       Fig 13: Removing Bolts, Nuts And Instrument Panel Reinforcement

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. REMOVE AIR CONDITIONER UNIT ASSY 
    1. Remove the 2 nuts and air conditioner unit assy.

       HINT:

       Make sure to keep the air conditioner unit assy unmoved as the installation parts of the bracket in the air conditioner unit assy could be damaged.

    Fig 14: Removing Nuts And Air Conditioner Unit Assy
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. REMOVE AIR DUCT NO. 2 
    1. Remove the screw.
    2. Release the 2 claw fittings and remove the air duct No. 2.
    Fig 15: Removing Air Duct No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. REMOVE WIRING AIR INDICATOR HARNESS SUB-ASSY NO. 2 
    1. Remove the 3 screws.
    2. Remove the clamp and disconnect the 2 connectors.
    Fig 16: Removing Wiring Air Indicator Harness Sub-Assy No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. REMOVE BLOWER ASSY 
    1. Remove the screw.
    2. Release the claw fitting and remove the blower assy.
    Fig 17: Removing Blower Assy
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. REMOVE HEATER TO REGISTER DUCT CENTER 
    1. Release the 4 claw fittings and remove the heater to register duct center.
       Fig 18: Releasing 4 Claw Fittings And Removing Heater To Register Duct Center

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. REMOVE MODE DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and mode damper servo sub-assy.
       Fig 19: Removing Screws And Mode Damper Servo Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. REMOVE AIR MIX DAMPER SERVO SUB-ASSY 
    1. LH side:

       Remove the 3 screws and air mix damper servo sub-assy.

       Fig 20: Removing Screws And Air Mix Damper Servo Sub-Assy (LH Side)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. RH side:

       Remove the 3 screws and air mix damper servo sub-assy.

       Fig 21: Removing Screws And Air Mix Damper Servo Sub-Assy (RH Side)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
37. REMOVE COOLER THERMISTOR NO. 1 
    1. Release the clamp and connector.
    2. Release the 2 claw fittings and remove cooler thermistor No. 1.
    Fig 22: Removing Cooler Thermistor No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. REMOVE HEATER RADIATOR UNIT SUB-ASSY 
    1. Remove the 2 screws and piping cover.
       Fig 23: Removing Screws And Piping Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw and bracket.
       Fig 24: Removing Screw And Bracket

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the heater radiator unit sub-assy.
       NOTE: Prepare a drain pan or cloth for when the cooling water leaks.
       Fig 25: Removing Heater Radiator Unit Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
39. REMOVE AIR CONDITIONING TUBE ASSY 
    1. Remove the packing.
       Fig 26: Removing Packing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and air conditioning tube assy.
    Fig 27: Removing Hexagon Bolts And Air Conditioning Tube Assy
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the air conditioning tube assy.
40. REMOVE COOLER EXPANSION VALVE 
    1. Remove the cooler expansion valve from the cooler evaporator sub-assy No. 1.
       Fig 28: Removing Cooler Expansion Valve

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. REMOVE COOLER EVAPORATOR SUB-ASSY NO. 1 
    1. Remove the 3 screws and air duct sub-assy.
       Fig 29: Removing Screws And Air Duct Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 4 claw fittings and remove the air duct sub-assy.
       Fig 30: Releasing Claw Fittings And Removing Air Duct Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 11 screws and separate the heater case.
    Fig 31: Removing Heater Case Screws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the cooler evaporator sub-assy No. 1.
    5. Remove the 2 O-rings from the cooler evaporator sub-assy No. 1.
       Fig 32: Removing O-Rings From Cooler Evaporator Sub-Assy No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
42. INSTALL COOLER EVAPORATOR SUB-ASSY NO. 1 
    1. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the cooler expansion valve.

       Compressor oil: ND-OIL8 or equivalent 

    2. Install the 2 O-rings on the cooler evaporator sub-assy No. 1.
       Fig 33: Installing O-Rings From Cooler Evaporator Sub-Assy No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cooler evaporator sub-assy No. 1 to the heater case.
    4. Install the heater case with the 11 screws.
       Fig 34: Installing Heater Case Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the air duct sub-assy with the 4 claws.
       Fig 35: Installing Air Duct Sub-Assy With Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the air duct sub-assy with the 3 screws.
       Fig 36: Installing Air Duct Sub-Assy And Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL COOLER EXPANSION VALVE 
    1. Install the cooler expansion valve to the cooler evaporator sub-assy No. 1.
       Fig 37: Installing Cooler Expansion Valve To The Cooler Evaporator Sub-Assy No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
44. INSTALL AIR CONDITIONING TUBE ASSY 
    1. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the air conditioning tube assy.

       Compressor oil: ND-OIL8 or equivalent 

    2. Install the 2 O-rings on the air conditioning tube assy.
    3. 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) 

       Fig 38: Installing Air Conditioning Tube Assy With Hexagon Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the packing.
       NOTE:

       • Be sure to install the packing securely so that there is no clearance.
       • Wrap the packing as shown in the illustration to keep out moisture.
         Fig 39: Installing Packing

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
45. INSTALL AIR DUCT NO. 2 
    1. Install the air duct No. 2 with the screw.

       Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf) 

       Fig 40: Installing Air Duct No. 2 With Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
46. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSY 
    1. Temporarily tighten the air conditioner unit assy with the 2 nuts.

       HINT:

       Make sure to keep the air conditioner unit assy unmoved as the installation parts of the bracket in the air conditioner unit assy could be damaged.

       Fig 41: Tightening Air Conditioner Unit Assy And Nuts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
47. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY 
    1. Install the instrument panel reinforcement with the 8 bolts.

       Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

       Fig 42: Installing Instrument Panel Reinforcement With Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily tighten the air conditioner unit assy with the 2 nuts and bolt.
       Fig 43: Temporarily Tightening Air Conditioner Unit Assy With Nuts And Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 bolts and 4 nuts.
    Fig 44: Installing Bolts And Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the clamps.
    5. Connect the connectors.
48. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO. 2 
    1. Install the instrument panel brace sub-assy No. 2 with the 3 bolts and 2 nuts.
    2. Install the clamps and connect the connectors.
    Fig 45: Installing Instrument Panel Brace Sub-Assy No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
49. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO. 1 
    1. Install the instrument panel brace sub-assy No. 1 with the 3 bolts and 2 nuts.
    2. Install the clamps and connect the connectors.
    Fig 46: Installing Instrument Panel Brace Sub-Assy No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
50. INSTALL AIR DUCT SUB-ASSY NO. 1 
    1. Install the air duct sub-assy No. 1 with the 3 nuts.

       Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

       NOTE: Tighten the bolts in numerical order shown in the illustration to install the air duct sub-assy No. 1.
       Fig 47: Installing Air Duct Sub-Assy No. 1 With Nuts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
51. FULLY TIGHTEN AIR CONDITIONER UNIT ASSY 
    1. Fully tighten the air conditioner unit assy with the 3 bolts and 4 nuts.

       Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

       NOTE:

       • Tighten the bolts in numerical order shown in the illustration to install the air conditioner unit assy.
       • Install the air conditioner unit assy so that there is no clearance between the duct and blower assy.
       Fig 48: Tightening Air Conditioner Unit Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
52. INSTALL AIR DUCT NO. 1 
    1. Install the air duct No. 1 with the bolt.

       Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

       Fig 49: Installing Air Duct No. 1 And Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
53. INSTALL STEERING COLUMN ASSY 

    MANUAL TILT: (see OVERHAUL )

    POWER TILT & TELESCOPIC: (see OVERHAUL )

54. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY 

    MANUAL TILT: (see OVERHAUL )

    POWER TILT & TELESCOPIC: (see OVERHAUL )

55. INSTALL ECM (SEE  ECM (3MZ-FE)  ) 
56. INSTALL SHIFT LEVER ASSY (SEE  OVERHAUL  ) 
57. CONNECT TRANSMISSION CONTROL CABLE ASSY (SEE  OVERHAUL  ) 
58. INSPECT SHIFT LEVER POSITION (SEE  OVERHAUL  ) 
59. ADJUST SHIFT LEVER POSITION (SEE  ADJUSTMENT  ) 
60. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (SEE  REPLACEMENT  ) 
61. INSTALL COOLER REFRIGERANT SUCTION HOSE NO. 1 
    1. Remove the attached vinyl tape from the hose.
    2. Coat a new O-ring with compressor oil and install it to the hose.

       Compressor oil: ND-OIL 8 or equivalent 

    3. Install the cooler refrigerant suction hose No. 1 and piping clamp.

       HINT:

       • Be sure to connect the hose securely.
       • After connection, check the fitting for claw of the piping clamp.
    Fig 50: Installing Cooler Refrigerant Suction Hose No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
62. INSTALL LIQUID TUBE SUB-ASSY A 
    1. Remove the attached vinyl tape from the hose.
    2. Coat a new O-ring with compressor oil and install it to the pipe.

       Compressor oil: ND-OIL 8 or equivalent 

    3. Install the liquid tube sub-assy A and piping clamp.

       HINT:

       • Be sure to connect the hose securely.
       • After connection, check the fitting for claw of the piping clamp.
    Fig 51: Installing Liquid Tube Sub-Assy A
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
63. INSTALL COWL TOP PANEL SUB-ASSY OUTER 
    1. Install the cowl top panel sub-assy outer with the 4 bolts and 6 nuts.

       Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) (NUT A) 

64. INSTALL FRONT SHOCK ABSORBER CAP LH (W/AIR SUSPENSION) (SEE  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
65. INSTALL FRONT SHOCK ABSORBER CAP RH (W/AIR SUSPENSION) (SEE  PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY  ) 
66. ADD ENGINE COOLANT (SEE  ENGINE COOLANT (3MZ-FE)  ) 
67. CHARGE REFRIGERANT (SEE  REPLACEMENT  ) 

    SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,

    07117-88060, 07117-88070, 07117-88080)

    Specified amount: 600 +/- 50 g (21.15 +/- 1.76 oz.) 

68. WARM UP ENGINE (SEE  REPLACEMENT  ) 
69. CHECK FOR ENGINE COOLANT LEAKS (SEE  COOLING SYSTEM (3MZ-FE)  ) 
70. INSPECT LEAKAGE OF REFRIGERANT (SEE  REPLACEMENT  )