Air Conditioning Radiator ASSY: Overhaul

HINT:

See 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. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO. 1 
   1. Install SST to piping clamp.

      SST 09870-00015

      HINT:

      Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label.

   2. Push down SST and release the clamp lock.
      Fig 1: Pushing Down SST & Releasing Clamp Lock

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to deform the tube, when pushing SST.
   3. Pull SST slightly and push the release lever, then remove the piping clamp with SST.
   4. Disconnect the cooler refrigerant suction hose No. 1.
      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 2: Disconnecting Cooler Refrigerant Suction Hose No.1

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A 

   SST 09870-00025

   HINT:

   Disconnect cooler refrigerant liquid pipe A in the same way as the cooler refrigerant suction hose No. 1.

4. DISCONNECT HEATER OUTLET WATER HOSE 
   1. Using pliers, grip the claws of clip and slide the clip and disconnect the heater outlet water hose.
      Fig 3: Disconnecting Heater Outlet Water Hose

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

   HINT:

   Disconnect in the same way as the heater outlet water hose.

6. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See  REPLACEMENT  ,  REPLACEMENT  ) 

   HINT:

   Refer to INSTRUMENT PANEL SAFETY PAD SUB-ASSY (From July, 2003) , INSTRUMENT PANEL SAFETY PAD SUB-ASSY .

7. REMOVE AIR DUCT REAR NO.1 
   1. Remove the 2 screws, bolt and nut.
   2. Remove the air duct rear No. 1.
      Fig 4: Removing Air Duct Rear No.1

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE AIR DUCT REAR NO.2 
   1. Remove the 2 screws, bolt and nut.
   2. Remove the air duct rear No. 2.
      Fig 5: Removing Air Duct Rear No.2

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE CONSOLE BOX DUCT NO.1 
   1. Remove the clip and console box duct No. 1.
      Fig 6: Removing Console Box Duct No.1

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY 
11. REMOVE WINDSHIELD WIPER RELAY ASSY 
12. REMOVE HEADLAMP LEVELING ECU ASSY 
13. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1 
    1. Remove the bolt and earth wire.
       Fig 7: Removing Earth Wire

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 2 clamps.
       Fig 8: Releasing Clamps

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and screw.
    4. Remove the nut and instrument panel brace sub-assy No. 1.
       Fig 9: Removing Instrument Panel Brace Sub-Assy No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER 
    1. Remove the 2 bolts and instrument finish retainer lower.
       Fig 10: Removing Instrument Finish Retainer Lower

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2 
    1. Remove the 2 clamps, nut and passenger side junction block.
       Fig 11: Removing Instrument Panel Brace Sub-Assy No.2

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 earth wires.
       Fig 12: Removing Earth Wires

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, bolt and instrument panel brace sub-assy No. 2.
       Fig 13: Removing Instrument Panel Brace Sub-Assy No. 2

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE HEATER TO FOOT DUCT NO.3 
    1. Remove the clip and heater to foot duct No. 3.
       Fig 14: Removing Heater To Foot Duct No. 3

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE HEATER TO FOOT DUCT NO.1 
    1. Remove the clip and heater to foot duct No. 1.
       Fig 15: Removing Heater To Foot Duct No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. DISCONNECT STEERING COLUMN ASSY 
    1. Remove the 3 nuts and driver side junction block.
       Fig 16: Removing Driver Side Junction Block

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and steering side connector block.
       Fig 17: Removing Steering Side Connector Block

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the 2 clamps.
    4. Remove the 3 bolts, disconnect the steering column assy.
       Fig 18: Disconnecting Steering Column Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Disconnect the 10 clamps and the wire harness.
       Fig 19: Disconnecting Clamps & Wire Harness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts, disconnect the 3 earth wires.
       Fig 20: Disconnecting Earth Wires

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 caps, 7 bolts and instrument panel reinforcement.
       Fig 21: Removing Instrument Panel Reinforcement

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE BLOWER ASSY 
    1. Disconnect the connectors.
    2. Remove the screw, clamp and blower connector holder.
       Fig 22: Removing Blower Connector Holder

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 6 clamps and the wire harness.
       Fig 23: Disconnecting Clamps & Wire Harness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 screws, 2 nuts and blower assy.
       Fig 24: Removing Blower Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE DEFROSTER NOZZLE ASSY LOWER 
    1. Release the 4 fitting claws, remove the defroster nozzle assy lower.
       Fig 25: Removing Defroster Nozzle Assy Lower

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE AIR CONDITIONING RADIATOR ASSY 
    1. Remove the 2 nuts and air conditioning radiator assy.
       Fig 26: Removing Air Conditioning Radiator Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE MODE DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and mode damper servo sub-assy.
    Fig 27: Removing Mode Damper Servo Sub-Assy

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE AIRMIX DAMPER SERVO SUB-ASSY 
    1. LH side:

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

       Fig 28: Removing Airmix Damper Servo Sub-Assy

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

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

       Fig 29: Removing Air Mix Damper Servo Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE HEATER RADIATOR UNIT SUB-ASSY 
    1. Release the 2 fitting claws, remove the piping clamp.
    2. Remove the heater radiator unit sub-assy.
       NOTE: Prepare a support plate and waste to catch the leaked coolant.
       Fig 30: Removing Heater Radiator Unit Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE AIR CONDITIONING TUBE ASSY 
    1. Remove the packing.
       Fig 31: Removing Packing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts and air conditioning tube assy.
       Fig 32: Removing Air Conditioning Tube Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the air conditioning tube assy.
27. REMOVE COOLER EXPANSION VALVE 
    1. Remove the cooler expansion valve from the cooler evaporator sub-assy No. 1.
       Fig 33: Removing Cooler Expansion Valve

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. REMOVE COOLER THERMISTOR NO.1 
29. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1 
    1. Release the fitting claw, remove the 3 screws and air duct sub-assy.
       Fig 34: Releasing Claw & Removing Air Duct Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 4 fitting claws, remove the air duct sub-assy.
       Fig 35: Releasing Claws & Removing Air Duct Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 11 screws and heater case LH.
       Fig 36: Removing Heater Case LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the cooler evaporator sub-assy No. 1 from the heater case RH.
    5. Remove the 2 O-rings from the cooler evaporator sub-assy No. 1.
       Fig 37: Removing O-Rings From Cooler Evaporator Sub-Assy No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1 
    1. Apply compressor oil to the contact surfaces of 2 new O-rings and the cooler expansion valve and install them.

       Compressor oil: ND-OIL 8 or equivalent 

       Fig 38: Installing Cooler Expansion Valve

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cooler evaporator sub-assy No. 1 to the heater case RH.
       Fig 39: Installing Cooler Evaporator Sub-Assy No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the heater case LH with the 11 screws.
    4. Install the air duct sub-assy.
       Fig 40: Installing Air Duct Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the air duct sub-assy with the 3 screws.
       Fig 41: Installing Air Duct Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. INSTALL COOLER EXPANSION VALVE 
    1. Install the cooler expansion valve to the cooler evaporator No. 1.
       Fig 42: Installing Cooler Expansion Valve To Cooler Evaporator No.1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSTALL AIR CONDITIONING TUBE ASSY 
    1. Apply compressor oil to the contact surfaces of 2 new O-rings and the air conditioning tube assy and install them.

       Compressor oil: ND-OIL 8 or equivalent 

    2. Using a hexagon wrench 4 mm (0.16 in.), install the air conditioner tube assy and 2 hexagon bolts to the cooler evaporator sub-assy No. 1.

       Torque: 3.5 N.m (35 kgf.cm, 30 in.lbf) 

       Fig 43: Installing Air Conditioning Tube Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the packing.

       HINT:

       Securely attach so that the gap in the packing will not be mode.

       Fig 44: Installing Packing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. INSTALL AIR CONDITIONING RADIATOR ASSY 
    1. Install the air conditioning radiator assy with the 2 nuts.

       Torque: 1.5 N.m (15 kgf.cm, 12 in.lbf) 

       Fig 45: Installing Air Conditioning Radiator Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. INSTALL DEFROSTER NOZZLE ASSY LOWER 
    1. Install the defroster nozzle assy lower.
       NOTE: After locating the pin (1) in Fig 46 , install (2), then (3).
       Fig 46: Installing Defroster Nozzle Assy Lower

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. INSTALL BLOWER ASSY 
    1. Install the blower assy with the 2 screws and 2 nuts.

       Torque: 1.5 N.m (15 kgf.cm, 12 in.lbf) 

       Fig 47: Installing Blower Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 6 clamps, connect the wire harness.
       Fig 48: Connecting Wire Harness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the blower connector holder with the screw.
       Fig 49: Installing Blower Connector Holder

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connectors.
36. INSTALL INSTRUMENT PANEL REINFORCEMENT 
    1. Install the instrument panel reinforcement with the 7 bolts and 3 caps.

       Torque: 20 N.m (203 kgf.cm, 14 ft.lbf) (Bolt A) 

       Fig 50: Installing Instrument Panel Reinforcement

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 earth wires with the 3 nuts.

       Torque: 8.4 N.m (85 kgf.cm, 73 in.lbf) 

       Fig 51: Installing Earth Wires

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 10 clamps, connect the wire harness.
       Fig 52: Installing Connecting Wire Harness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
37. INSTALL STEERING COLUMN ASSY 
    1. Install the steering column assy with the 3 bolts.
       Fig 53: Installing Steering Column Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 clamps.
    3. Install the steering side connector block with the 2 nuts.
       Fig 54: Installing Steering Side Connector Block

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the driver side junction block with the 3 nuts.

       Torque: 8.4 N.m (85 kgf.cm, 73 in.lbf) 

       Fig 55: Installing Driver Side Junction Block

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2 
    1. Install the instrument panel brace sub-assy No. 2 with the 2 nuts and bolt.
       Fig 56: Installing Instrument Panel Brace Sub-Assy No. 2

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 earth wires with the 2 bolts.

       Torque: 8.4 N.m (85 kgf.cm, 73 in.lbf) 

       Fig 57: Installing Earth Wires

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the passenger side junction block with the nut and 2 clamps.

       Torque: 8.4 N.m (85 kgf.cm, 73 in.lbf) 

       Fig 58: Installing Passenger Side Junction Block

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
39. INSTALL INSTRUMENT FINISH PANEL RETAINER LOWER 
    1. Install the instrument finish panel retainer lower with the 2 bolts.
       Fig 59: Installing Instrument Finish Panel Retainer Lower

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
40. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1 
    1. Install the instrument panel brace sub-assy No. 1 with the nut.
       Fig 60: Installing Instrument Panel Brace Sub-Assy No.

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt and screw.

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

    3. Install the 2 clamps.
       Fig 61: Installing Clamps

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the earth wire with the bolt.

       Torque: 8.4 N.m (85 kgf.cm, 73 in.lbf) 

       Fig 62: Installing Earth Wire

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See  REPLACEMENT  ,  REPLACEMENT  ) 
42. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 
    1. Lubricate new O-ring with compressor oil and install them to the hose.

       Compressor oil: ND-OIL 8 or equivalent 

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

       HINT:

       After connection, check the fitting for claw of the piping clamp.

    Fig 63: Installing Cooler Refrigerant Suction Hose No. 1

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL COOLER REFRIGERANT LIQUID PIPE A 

    HINT:

    Install in the same way as the cooler refrigerant suction hose No. 1.

44. ADD COOLANT  
45. 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: 550 +/- 50 g (19.37 +/- 1.76 oz.) 

46. WARM UP ENGINE 
47. CHECK ENGINE COOLANT LEAK  
48. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT   )