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Air Conditioner Unit ASSY: Overhaul

WARNING: This page is about a different car, the 2004 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

COMPONENT: 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.

      Fig 1: Installing SST To Piping Clamp
      G02900185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down SST and release the clamp lock.
      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. Remove the piping clamp from SST.
      Fig 2: Pushing Down SST And Release Clamp Lock
      G02900186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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 3: Disconnecting Cooler Refrigerant Suction Hose
    G02900187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A 

    SST 09870-00015

    HINT:

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

  4. DISCONNECT HEATER INLET WATER HOSE 
    1. Using pliers, grip the claws of clip and slide the clip and disconnect the heater inlet water hose.
    Fig 4: Disconnecting Heater Inlet Water Hose
    G02900188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT HEATER OUTLET WATER HOSE 

    HINT:

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

  6. REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (See  REPLACEMENT  ) 

    HINT:

    Refer to the instructions for removal of the instrument panel sub-assy lower.

  7. REMOVE INSTRUMENT PANEL LWR PAD INSERT LH 
    1. Remove the 3 screws and instrument panel LWR pad insert LH.
    Fig 5: Removing Instrument Panel LWR Pad Insert LH
    G02900189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 1 
    1. Remove 2 clips and take up the floor carpet.

      HINT:

      Take up the floor carpet as small as the instrument panel brace sub-assy No. 1 can be removed.

      Fig 6: Removing Clips And Take Up Floor Carpet
      G02900190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp and floor shift parking lock cable assy.
      Fig 7: Removing Clamp And Floor Shift Parking Lock Cable Assy
      G02900191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
    4. Remove the bolt, nut and instrument panel brace sub-assy No. 1.
    Fig 8: Removing Instrument Panel Brace Sub-Assy
    G02900192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE AIR DUCT NO. 1 
    1. Release the 2 fitting claws, remove the air duct No. 1.
    Fig 9: Removing Air Duct No. 1
    G02900193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE AIR DUCT NO. 2 
    1. Remove the screw.
    2. Release the 2 fitting claws, remove the air duct No. 2.
    Fig 10: Remove Air Duct No. 2
    G02900194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE AIR DUCT REAR NO. 3 (W/ COLD AREA) 
    1. Release the 6 fitting claws, remove the air duct rear No. 3.
    Fig 11: Removing Air Duct Rear No. 3
    G02900195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE AIR DUCT REAR NO. 4 (W/ COLD AREA) 
    1. Remove 2 clips and take up the floor carpet.

      HINT:

      Take up the floor carpet as small as the air duct rear No. 4 can be removed.

      Fig 12: Removing Clips And Take Up Floor Carpet
      G02900196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 6 fitting claws, remove the air duct rear No. 4.
    Fig 13: Releasing Fitting Claws
    G02900197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE HEATER TO REGISTER DUCT NO. 2 
    1. Remove the 2 clips and heater to register duct No. 2.
    Fig 14: Removing Heater To Register Duct No. 2
    G02900198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE HEATER TO REGISTER DUCT NO. 1 
    1. Remove the 2 clips and heater to register duct No. 1.
    Fig 15: Removing Heater To Register Duct No. 1
    G02900199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE DEFROSTER NOZZLE ASSY 
    1. Release the 3 fitting claws, remove the defroster nozzle assy.
    Fig 16: Removing Defroster Nozzle Assy
    G02900200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSY 
    1. Disconnect the outer cable from the clamp.
    2. Disconnect the inner cable and defroster damper control cable sub-assy.
    NOTE:
    • Be careful not to bend the cable wire.
    • If the cable wire bends, the heater control & accessory assy operationally becomes worse.
    Fig 17: Disconnecting Defroster Damper Control Cable Sub-Assy
    G02900201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSY 
    1. Disconnect the outer cable from the clamp.
    2. Disconnect the inner cable and air mix damper control cable sub-assy.
    NOTE:
    • Be careful not to bend the cable wire.
    • If the cable wire bends, the heater control & accessory assy operationally becomes worse.
    Fig 18: Disconnecting Air Mix Damper Control Cable Sub-Assy
    G02900202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT ECM 
    1. Remove the 2 bolts and disconnect the ECM.
    NOTE:
    • Do not apply excessive force to the connector of the ECM.
    • Do not give any impact to the ECM.
    Fig 19: Disconnecting ECM
    G02900203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER 
    1. Remove the 2 nuts and instrument panel to cowl brace center.
    Fig 20: Removing Instrument Panel To Cowl Brace Center
    G02900204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT STEERING COLUMN ASSY 
    1. Disconnect the connector, remove the 2 clamps.
      Fig 21: Disconnecting Connector
      G02900205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, disconnect the steering column assy.
    Fig 22: Disconnecting Steering Column Assy
    G02900206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Remove the 8 screws and 2 earth wires from the instrument panel reinforcement.
      Fig 23: Removing Instrument Panel Reinforcement
      G02900207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 6 clamps and wire harness.
      Fig 24: Disconnecting Clamps And Wire Harness
      G02900208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and instrument panel reinforcement.
    Fig 25: Removing Instrument Panel Reinforcement
    G02900209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE AIR CONDITIONER UNIT ASSY 
    1. Release the 2 fitting claws, disconnect the connector holder.

      HINT:

      Release the claw while pressing the lock part in the arrow direction.

      Fig 26: Disconnecting Connector Holder
      G02900210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the blower w/ fan motor sub-assy.
      Fig 27: Disconnecting Connector From Blower W/ Fan Motor Sub-Assy
      G02900211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector from the damper servo sub-assy.
      Fig 28: Disconnecting Connector From Damper Servo Sub-Assy
      G02900212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector from the cooler thermistor No. 1.
      Fig 29: Disconnecting Connector From Cooler Thermistor No. 1
      G02900213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 nuts, bolt and air conditioner unit assy.
    Fig 30: Removing Air Conditioner Unit Assy
    G02900214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE AIR FILTER CASE 
    1. Release the 2 fitting claws, remove the air filter case.
    Fig 31: Removing Air Filter Case
    G02900215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE AIR FILTER 
    1. Remove the air filter from the air conditioner unit assy.

    HINT:

    Removing only the glove compartment door assy makes it possible and install the air filter.

    Fig 32: Removing Air Filter
    G02900216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE DAMPER SERVO SUB-ASSY 
    1. Remove the 2 screws and damper servo sub-assy.

    HINT:

    Removing only instrument panel sub-assy upper and heater to register duct No. 1 makes it possible and install the damper servo sub-assy.

    Fig 33: Removing Damper Servo Sub-Assy
    G02900217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BLOWER W/FAN MOTOR SUB-ASSY 
    1. Remove the 3 screws and blower w/ fan motor sub-assy.

    HINT:

    Removing only the ECM makes it possible and install the blower w/fan motor sub-assy.

    Fig 34: Removing Blower W/Fan Motor Sub-Assy
    G02900218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE BLOWER RESISTOR 
    1. Disconnect the connector.
    2. Remove the 2 screws and blower resistor.

    HINT:

    Removing only the ECM makes it possible and install the blower resistor.

    Fig 35: Removing Blower Resistor
    G02900219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HEATER PIPING COVER 
    1. Release the 3 fitting claws, remove the heater piping cover.
    Fig 36: Removing Heater Piping Cover
    G02900220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE HEATER RADIATOR UNIT SUB-ASSY 
    1. Release the 3 fitting claws, remove the heater piping clamp and heater radiator unit sub-assy
    Fig 37: Removing Heater Radiator Unit Sub-Assy
    G02900221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE COOLER THERMISTOR NO. 1 
    1. Remove the clamp.
      Fig 38: Removing Clamp
      G02900222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the fitting claw, remove the 2 screws and heater case.
      Fig 39: Removing 2 Screws And Heater Case
      G02900223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the fitting claw, remove the 5 screws and heater case.
      Fig 40: Removing 5 Screws And Heater Case
      G02900224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the cooler thermistor No. 1 from the cooler evaporator sub-assy No. 1.
    Fig 41: Removing Cooler Thermistor No. 1 From Cooler Evaporator Sub-Assy No. 1
    G02900225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE AIR CONDITIONING TUBE ASSY 
    1. Remove the cooler evaporator assy from the heater case.
    2. Remove the packing.
      Fig 42: Removing Cooler Evaporator Assy From Heater Case
      G02900226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a hexagon wrench 5.0 mm (0.20 in.), remove the 2 hexagon bolts and air conditioning tube assy.
    4. Remove the 2 O-rings from the air conditioning tube assy.
    Fig 43: Removing O-Rings From Air Conditioning Tube Assy
    G02900227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE COOLER EXPANSION VALVE 
    1. Remove the cooler expansion valve from the cooler evaporator sub-assy No. 1.
    2. Remove the 2 O-rings from the cooler evaporator sub-assy No. 1.

    HINT:

    Removing only instrument panel sub-assy upper, heater to register duct No. 1 and heater case makes it possible and install the cooler expansion valve.

    Fig 44: Removing Cooler Expansion Valve
    G02900228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE COOLER EVAPORATOR SUB-ASSY NO. 1 
  34. REMOVE COOLER UNIT DRAIN HOSE NO. 1 
  35. INSTALL COOLER EXPANSION VALVE 
    1. Lubricate 2 new O-rings with compressor oil and install them to the cooler expansion valve.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the cooler expansion valve from cooler evaporator sub-assy No. 1.
    Fig 45: Installing Cooler Expansion Valve
    G02900229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL AIR CONDITIONING TUBE ASSY 
    1. Lubricate 2 new O-rings with compressor oil and install them to the air conditioning tube assy.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Using a hexagon wrench 5.0 mm (0.20 in.), install the air conditioning tube assy with the 2 hexagon bolts.

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

      Fig 46: Installing Air Conditioning Tube Assy
      G02900230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the packing.

      HINT:

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

    4. Install the cooler evaporator assy to the heater case.
    Fig 47: Installing Packing
    G02900231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL COOLER THERMISTOR NO. 1 
    1. Install the cooler thermistor No. 1 at the shown position on the illustration.
      Fig 48: Installing Cooler Thermistor No. 1
      G02900232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the heater case with the claw and 5 screws.
      Fig 49: Installing Heater Case With Claw And 5 Screws
      G02900233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the heater case with the claw and 2 screws.
    Fig 50: Installing Heater Case With Claw And 2 Screws
    G02900234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL AIR FILTER 
    1. Install the air filter to the air conditioner unit assy.
    Fig 51: Installing Air Filter
    G02900235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL AIR CONDITIONER UNIT ASSY 
    1. Install the air conditioner unit assy with the 4 nuts and bolt.

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

      NOTE: Tighten the nuts and bolt in following order shown in the illustration to install the air conditioner unit assy.
      Fig 52: Installing Air Conditioner Unit Assy
      G02900236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector to the cooler thermistor No. 1.
      Fig 53: Connecting Connector To Cooler Thermistor No. 1
      G02900237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector to the damper servo sub-assy.
      Fig 54: Connecting Connector To Damper Servo Sub-Assy
      G02900238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector to the blower w/ fan motor sub-assy.
      Fig 55: Connecting Connector To Blower W/ Fan Motor Sub-Assy
      G02900239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 fitting claws, connect the connector holder.
    Fig 56: Installing Fitting Claws
    G02900240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL ECM 
    1. Install the ECM with the 2 bolts.

      Torque: 3.0 N.m (30 kgf.cm, 26 in..lbf) 

    NOTE:
    • Do not apply excessive force to the connector of the ECM.
    • Do not give any impact to the ECM.
    Fig 57: Installing ECM
    G02900241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER (See  REPLACEMENT  ) 
  42. INSTALL HEATER CONTROL & ACCESSORY ASSY (See  HEATER CONTROL & ACCESSORY ASSY  ) 
  43. INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSY 
    1. Set the arm in FACE position.
    2. Install the inner cable end to the control lever with the arm in FACE position.
    3. Install the outer cable to the cable clamp while slightly pressing it in the direction of the arrow.
    NOTE:
    • Be careful not to bend the cable wire.
    • If the cable wire bends, the heater control & accessory assy operationally becomes worse.

    HINT:

    Operating the mode control lever, check that it properly stops at both ends of FACE and DEF and no recoil is identified.

    Fig 58: Installing Defroster Damper Control Cable Sub-Assy
    G02900242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSY 
    1. Set the arm in MAX. COOL position.
    2. Install the inner cable end to the control lever with the arm in MAX. COOL position.
    3. Install the outer cable to the cable clamp while slightly pressing it in the direction of the arrow.
    NOTE:
    • Be careful not to bend the cable wire.
    • If the cable wire bends, the heater control & accessory assy operationally becomes worse.

    HINT:

    Operating the temperature control lever, check that it properly stops at both ends of MAX. COOL and MAX. HOT and no recoil is identified.

    Fig 59: Installing Air Mix Damper Control Cable Sub-Assy
    G02900243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE HEATER CONTROL & ACCESSORY ASSY (See  HEATER CONTROL & ACCESSORY ASSY  ) 
  46. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (See  REPLACEMENT  ) 
  47. INSTALL HEATER OUTLET WATER HOSE 
    1. Using pliers, grip the claws of clip and slide the clip and connect the heater outlet water hose.
    NOTE:
    • The clip is installing so that the projection of the clip may go into the 90° to a direction position.
    • Marking of hose is installed upward by vehicle.
    Fig 60: Installing Heater Outlet Water Hose
    G02900244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL HEATER INLET WATER HOSE 

    HINT:

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

  49. INSTALL COOLER REFRIGERANT SUCTION HOSE NO. 1 
    1. Lubricate a 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 61: Installing Cooler Refrigerant Suction Hose No. 1
    G02900245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL COOLER REFRIGERANT LIQUID PIPE A 
    1. Lubricate a new O-ring with compressor oil and install them to the pipe.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the cooler refrigerant liquid pipe A and piping clamp.

    HINT:

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

  51. ADD COOLANT (See  REPLACEMENT  ) 
  52. CHECK ENGINE COOLANT LEAK (See  ON-VEHICLE INSPECTION  ) 
  53. CHARGE REFRIGERANT (See  REPLACEMENT  ) 

    SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140

    Specified amount: 490 +/- 30 g (17.28 +/- 1.06 oz.) 

  54. WARM UP ENGINE 
  55. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
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