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Heater & Air Conditioner: Overhaul

HINT:

COMPONENTS: See COMPONENTS 

  1. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (See  REPLACEMENT  ) 
  2. REMOVE INTEGRATION CONTROL & PANEL ASSY (See  REPLACEMENT  ) 
  3. REMOVE RADIO RECEIVER ASSY (See  REPLACEMENT  ) 
  4. REMOVE CONTROL KNOB SUB-ASSY 
  5. REMOVE HEATER CONTROL NAME SHEET NO.1 (MANUAL AIR CONDITIONING) 
  6. REMOVE HEATER CONTROL NAME SHEET NO.2 
    1. Using a screwdriver protected by taping, remove the heater control name sheet No. 2.
    Fig 1: Removing Heater Control Name Sheet No. 2
    G03034481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE HEATER CONTROL HOUSING SUB-ASSY 
    1. Release the lock of connector and disconnect the cable.
    2. Remove the 8 screws and heater control housing.
    Fig 2: Removing 8 Screws Or Heater Control Housing
    G03034482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE AIR CONDITIONER AMPLIFIER ASSY 
    1. Remove the 3 screws and air conditioner amplifier assy from the heater control housing.
    Fig 3: Removing Screws And Air Conditioner Amplifier Assy
    G03034483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE HEATER BLOWER SWITCH (MANUAL AIR CONDITIONING) 


HINT:

COMPONENTS: See COMPONENTS , 71-6

  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 PIPE NO.1 
    1. Install SST on piping clamp.

      SST 09870-00015

      HINT:

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

      Fig 1: Installing SST On Piping Clamp
      G03034486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down the 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, and then remove the piping clamp with SST.
      Fig 2: Removing Piping Clamp
      G03034487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    5. Remove the 2 O-rings from the cooler refrigerant suction hose No.1.
    Fig 3: Removing O-Rings From Cooler Refrigerant Suction Hose
    G03034488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A 

    SST 09870-00025

    HINT:

    Disconnect of the cooler refrigerant liquid pipe A is same as the cooler refrigerant suction pipe No.1.

  4. 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
    G03034489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT HEATER INLET WATER HOSE 
    1. Disconnection of the heater inlet water hose is same as the heater outlet water hose.
  6. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See  REPLACEMENT  ) 

    SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

    HINT:

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

    Fig 5: Removing Bolts Or Nuts From Steering Column Assy
    G03034490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SEPARATE STEERING COLUMN ASSY 
    1. Remove the 2 bolts and 2 nuts, disconnect the steering column assy from the instrument panel reinforcement assy
    Fig 6: Removing Nuts From Shift Cable
    G03034491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. SEPARATE FLOOR SHIFT ASSY 
    1. Remove the 2 nuts and disconnect the shift cable.
      Fig 7: Removing Nuts From Transmission Floor Shift Assembly
      G03034492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and disconnect transmission floor shift assy.
  9. REMOVE AIR DUCT REAR NO.2 
    1. Remove the side scuff plate.
    2. Take up the floor carpet.

      HINT:

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

    3. Remove the air duct rear No.2.
    Fig 8: Removing Air Duct Rear
    G03034493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE AIR DUCT REAR NO.1 

    HINT:

    Remove it in the same way with the air duct rear no.2.

  11. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1 
    1. Disconnect the connector clamp.
    2. Remove the 3 bolts, 2 nuts and instrument panel brace sub-assy No.1.
    Fig 9: Removing Bolts Nuts From Instruments Panel Brace Subassy
    G03034494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2 
    1. Remove the 2 bolts, 2 nuts and instrument panel brace sub-assy No.2.
    Fig 10: Removing Bolts, Nuts From Panel Brace Sub Assy
    G03034495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE AIR CONDITIONER AMPLIFIER ASSY (W/ LEXUS NAVIGATION SYSTEM) (See  AIR CONDITIONER AMPLIFIER ASSY  ) 
    Fig 11: Removing Nuts Or ECU
    G03034496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE ECM 
    1. Disconnect the connector.
    2. Remove the 2 nuts, and ECU.
  15. REMOVE MULTIPLEX NETWORK BODY ECU 
    1. Disconnect the connector.
    2. Remove the 2 nuts and multiplex network body ECU.
    Fig 12: Removing Nuts Or Multiplex Net Work Body ECU
    G03034497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSY 
    1. Remove the bolt and 2 nuts, disconnect the instrument panel junction block assy.
    Fig 13: Removing Bolts Or Nuts From Junction Block Assembly
    G03034498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE SKID CONTROL ECU ASSY 
    1. Disconnect the connector.
    2. Remove the 2 nuts and skid control ECU assy.
    Fig 14: Removing Nuts From Skid Control ECU Assy
    G03034499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY 
    1. Remove the 5 bolts, 4 nuts and instrument panel reinforcement assy.
    Fig 15: Removing Bolts, Nuts From Instrument Panel Reinforcement Assy
    G03034500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE AIR CONDITIONER UNIT ASSY 
    1. Disconnect the connector and clamp.
      Fig 16: Disconnecting Connector
      G03034501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connectors connecting the wiring air indicator harness sub-assy and vehicle harness.
    3. Remove the 2 bolts, 2 nuts and air conditioner unit assy.
  20. REMOVE AIR CONDITIONING RADIATOR ASSY 
    1. Remove the screw, disconnect the connected part of the duct and take off the air duct No.2.
      Fig 17: Removing Air Conditioner Unit Assembly
      G03034502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 screws and bracket.
    3. Disconnect the connection between the blower assy and the air conditioner radiator assy and remove the air conditioning radiator assy.
    Fig 18: Removing Screws Or Bracket
    G03034503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE AIR DUCT NO.1 
    1. Release the 3 claw fittings, remove the air duct No.1.
    Fig 19: Removing Air Duct
    G03034504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE HEATER TO REGISTER DUCT CENTER 
    1. Release the 4 claw fittings, remove the heater to register duct center.
    Fig 20: Removing Claw Fittings Or Heater To Register Duct Center
    G03034505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE MODE DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and mode damper servo sub-assy.
    Fig 21: Removing Mode Damper Servo Sub-Assy
    G03034506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSY 
    1. Remove the wiring air conditioning harness sub-assy from the air conditioner radiator assy.
    Fig 22: Removing Wiring Air Conditioning Harness Sub-Assy From Air Conditioner Radiator Assy
    G03034507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE AIR MIX DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and air mix damper servo sub-assy.
    Fig 23: Removing Damper Servo Sub-Assembly
    G03034508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE HEATER RADIATOR UNIT SUB-ASSY 
    1. Remove the screw and clamp.
    2. Remove the heater radiator unit sub-assy from the air conditioner radiator assy.
    Fig 24: Removing Heater Radiator Unit Sub-Assy From Air Conditioner Radiator Assembly
    G03034509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE COOLER THERMISTOR NO.1 
  28. REMOVE BLOWER MOTOR CONTROL (AUTO AIR CONDITIONING) 
    1. Remove the 2 screws and blower motor control.
    Fig 25: Removing Screws From Blower Motor Control
    G03034510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE BLOWER RESISTOR (MANUAL AIR CONDITIONING) 
    1. Remove the 2 screws and blower resistor.
  30. REMOVE WIRING AIR INDICATOR HARNESS SUB-ASSY NO.2 
    1. Remove the wiring air indicator harness sub-assy No.2 from the blower motor control.
  31. REMOVE COOLER EXPANSION VALVE 
    1. Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts and cooler expansion valve.
    2. Remove the 2 O-rings from the air conditioner tube assy.
    Fig 26: Removing Hexagon Bolts With Using Hexagon Wrench
    G03034511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1 
    1. Remove the 11 screws and radiator case.
    2. Remove the cooler evaporator sub-assy No.1 from the air conditioner radiator assy.
      Fig 27: Removing Screws From Radiator Case
      G03034512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the cooler evaporator subassy No.1.
    Fig 28: Removing O-Rings From Cooler Evaporator Subassembly
    G03034513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1 
    1. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the coder evaporator sub-assy No.1.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the 2 O-rings on the coder evaporator sub-assy No.1.
      Fig 29: Installing O-Rings On Coder Evaporator Sub-Assemby
      G03034514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cooler evaporator No.1 to the air conditioner radiator assy.
    4. Install the evaporator cover with the 11 screws.
    Fig 30: Installing Evaporator Cover With Screws
    G03034515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL COOLER EXPANSION VALVE 
    1. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the air conditioning tube assy.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the 2 O-rings on the air conditioning tube assy.
    3. Using a hexagon wrench 4mm (0.15 in.), install the cooler expansion valve and 2 hexagon bolts to the cooler evaporator No.1.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lf) 

    Fig 31: Installing O-Rings On Air Conditioning Tube Assembly
    G03034516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL AIR CONDITIONER UNIT ASSY 
    1. Install the air conditioner unit assy with the 2 bolts and 2 nuts.

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

    2. Connect the connectors connecting the wiring air indicator No.2 harness and vehicle harness.
      Fig 32: Installing Air Conditioner Unit Assy With Bolts And Nuts
      G03034517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the connector and clamp.
    Fig 33: Installing Connector Or Clamp
    G03034518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY 
    1. Install the instrument panel reinforcement assy with the 5 bolts and 4 nuts.

      Torque: 29 N.m (300 kgf.cm, 21 ft.lbf) 

    Fig 34: Installing Instrument Panel Reinforcement Assy
    G03034519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL SKID CONTROL ECU ASSY 
    1. Install the skid control ECU assy with the 2 nuts.

      Torque: 5.0 N.m (50 kgf.cm, 43 in..lbf) 

    Fig 35: Installing Skid Control ECU Assy
    G03034520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY 
    1. Install the instrument panel junction block assy with the bolt and 2 nuts.

      Torque: 8.4 N.m (86 kgf.cm, 74 in..lbf) 

    Fig 36: Installing Instrument Panel Junction Block Assy
    G03034521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL ECM 
    1. Install the ECM with the 2 nuts.

      Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

    Fig 37: Installing ECM With Nut
    G03034522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2 
    1. Install the instrument panel brace sub-assy No.2 with the 2 bolts and 2 nuts.

      Torque: 29 N.m (300 kgf.cm, 21 ft.lbf) 

    Fig 38: Installing Instrument Panel Brace Sub-Assy
    G03034523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. 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.

      Torque: 29 N.m (300 kgf.cm, 21 ft.lbf) 

    Fig 39: Installing Instrument Panel Brace Sub-Assy
    G03034524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL FLOOR SHIFT ASSY 
    1. Install the floor shift assy with the 4 nuts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

      NOTE: Tighten the nuts in numerical order shown in the illustration to install the floor shift assy.
      Fig 40: Installing Floor Shift Assy
      G03034525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the shift cable with the 2 nuts.

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

    Fig 41: Installing Shift Cable With Nuts
    G03034526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL STEERING COLUMN ASSY 
    1. Install the steering column assy with the 2 bolts and 2 nuts.

      Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 

    Fig 42: Installing Steering Column Assy
    G03034527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See  REPLACEMENT  ) 
  45. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1 
    1. Remove the attached vinyl tape from the pipe.
    2. Coat a new O-ring with compressor oil and install them to the hose.

      Compressor oil: ND-OIL 8 or equivalent 

    3. Install the cooler refrigerant suction pipe No.1 and piping clamp.
    Fig 43: Removing Attached Vinyl Tape From Pipe
    G03034528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    • Be sure to connect the pipe securely.
    • After connection, check the fitting for claw of the piping clamp.
  46. INSTALL COOLER REFRIGERANT LIQUID PIPE A 
    1. Remove the attached vinyl tape from the pipe.
    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 cooler refrigerant liquid pipe A and piping clamp.
  47. ADD COOLANT 

    2AZ-FE: (See  REPLACEMENT  ) 

    3MZ-FE: (See  REPLACEMENT  ) 

  48. CHECK FOR ENGINE COOLANT LEAKS 

    2AZ-FE: (See  ON-VEHICLE INSPECTION  ) 

    3MZ-FE: (See  ON-VEHICLE INSPECTION  ) 

  49. 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: 650 +/- 50 g (22.93 +/- 1.76 oz.) 

  50. WARM UP ENGINE 
  51. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
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