Air Conditioning Radiator ASSY: Overhaul

HINT:

See COMPONENTS

DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See INSTRUMENT PANEL/METER )
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
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.
  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.
  
  Fig 1: Pushing Release Lever
  Courtesy 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.
  Fig 2: Disconnecting Cooler Refrigerant Suction Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT COOLER REFRIGERANT LIQUID PIPE A
SST 09870-00015

HINT:

Disconnect cooler refrigerant liquid pipe A in the same way as the cooler refrigerant suction hose No. 1.
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: Griping Claws Of Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT HEATER INLET WATER HOSE
HINT:

Disconnect in the same way as the heater outlet water hose.
REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See INSTRUMENT PANEL/METER )
HINT:

Refer to the instructions for removal of the instrument panel safety pad sub-assy.
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 Bolts Of Air Duct Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR DUCT REAR NO.2
1. Remove the bolt and nut.
2. A/X models:
  Remove the 2 screws, air duct rear No. 2 and console box mounting bracket No. 1.
3. M/X models:
  Remove the screw, air duct rear No. 2 and console box mounting bracket No. 1.
  
  Fig 5: Removing Screw Of Air Duct Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONSOLE BOX DUCT NO.1 (AUTO AIR CONDITIONING)
1. Remove the clip and console box duct No. 1.
  
  Fig 6: Removing Clip Of Console Box Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY
REMOVE WINDSHIELD WIPER RELAY ASSY
REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1
1. Remove the 2 bolts and 2 earth wires.
  
  Fig 7: Removing Bolts Of Instrument Panel Brace Sub-Assy
  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 Nut Of Instrument Panel Brace Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER
1. Remove the 2 bolts and instrument finish retainer lower.
  
  Fig 10: Removing Bolts Of Instrument Finish Retainer Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2
1. Remove the clamp, nut and passenger side junction block.
  
  Fig 11: Removing Clamp Of Passenger Side Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt and earth wire.
  
  Fig 12: Removing Bolt And Earth Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut and clamp.
  
  Fig 13: Removing Nut And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 nuts, bolt and instrument panel brace sub-assy No. 2.
  
  Fig 14: Removing Bolt Of Instrument Panel Brace Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER TO FOOT DUCT NO.3
1. Remove the clip and heater to foot duct No. 3.
  
  Fig 15: Removing Clip Of Heater To Foot Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HEATER TO FOOT DUCT NO.1
1. Remove the clip and heater to foot duct No. 1.
  
  Fig 16: Removing Clip Of Heater To Foot Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT STEERING COLUMN ASSY
1. Remove the 3 nuts and driver side junction block.
  
  Fig 17: Removing Nuts Of Driver Side Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 nuts and steering side connector block.
  
  Fig 18: Removing Nuts Of 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 19: Removing Bolts Of Steering Column Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INSTRUMENT PANEL REINFORCEMENT
1. Disconnect the 7 clamps and the wire harness.
  
  Fig 20: Disconnecting Clamps And Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts, disconnect the 3 earth wires.
  
  Fig 21: Removing Nuts Of Earth Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 caps, 7 bolts and instrument panel reinforcement.
  
  Fig 22: Removing Bolts Of Instrument Panel Reinforcement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BLOWER ASSY
1. Disconnect the connectors.
2. Remove the screw, clamp and blower connector holder.
  
  Fig 23: Removing Screw Of Blower Connector Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the 6 clamps and the wire harness.
  
  Fig 24: Disconnecting Clamps And Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 screws, 2 nuts and blower assy.
  
  Fig 25: Removing Screws Of Blower Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DEFROSTER NOZZLE ASSY LOWER
1. Release the 4 fitting claws, remove the defroster nozzle assy lower.
  
  Fig 26: Releasing Fitting Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CONDITIONING RADIATOR ASSY
1. Disconnect the connectors.
2. Remove the 2 nuts and air conditioning radiator assy.
  
  Fig 27: Removing Nuts Of Air Conditioning Radiator Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MODE DAMPER SERVO SUB-ASSY
1. Remove the 3 screws and mode damper servo sub-assy.
  
  Fig 28: Removing Screws Of Mode Damper Servo Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 29: Removing Fitting Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIRMIX DAMPER SERVO SUB-ASSY
1. Remove the 3 screws and air mix damper servo sub-assy.
  
  Fig 30: Removing Screws Of Air Mix Damper Servo Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
3. Remove the 2 O-rings from the air conditioning tube assy.
  
  Fig 32: Removing O-Rings From Air Conditioning Tube Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER EXPANSION VALVE
1. Remove the cooler expansion valve from the cooler evaporator sub-assy No. 1.
  
  Fig 33: Removing Cooler Expansion Valve From Cooler Evaporator Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOLER THERMISTOR NO.1
REMOVE COOLER EVAPORATOR SUB-ASSY NO.1
1. Auto A/C model:
  Release the fitting claw, remove the 3 screws and air duct sub-assy.
  
  Fig 34: Removing Screws Of Air Duct Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 12 screws and heater case LH.
3. Remove the cooler evaporator sub-assy No. 1 from the heater case RH.
  
  Fig 35: Removing Screws Of Heater Case LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 O-rings from the cooler evaporator sub-assy No. 1.
  
  Fig 36: Removing O-Rings From Cooler Evaporator Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 37: Installing Cooler Evaporator Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cooler evaporator sub-assy No. 1 to the heater case RH.
3. Install the heater case LH with the 12 screws.
  
  Fig 38: Removing Heater Case LH With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Auto A/C model:
  Install the air duct sub-assy with the 3 screws.
  
  Fig 39: Installing Air Duct Sub-Assy With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. Install the cooler expansion valve to the cooler evaporator No. 1.
  
  Fig 40: Installing Cooler Expansion Valve To Cooler Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 deg; Cm, 30 in..lbf)
  
  Fig 41: Installing Air Conditioner 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 42: Installing Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING RADIATOR ASSY
1. Install the air conditioning radiator assy with the 2 nuts.
  Torque: 1.5 N.m (15 kgf deg; Cm, 12 in..lbf)
2. Connect the connector.
  
  Fig 43: Installing Nut Of Air Conditioning Radiator Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DEFROSTER NOZZLE ASSY LOWER
1. Install the defroster nozzle assy lower.
  NOTE: After locating the pin (1) in the illustration, install (2), then (3).
  
  Fig 44: Installing Defroster Nozzle Assy Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER ASSY
1. Install the blower assy with the 2 screws and 2 nuts.
  Torque: 1.5 N.m (15 kgf deg; Cm, 12 in..lbf)
  
  Fig 45: Installing Screw Of Blower Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 6 clamps, connect the wire harness.
  
  Fig 46: Installing Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the blower connector holder with the screw and clamp.
4. Connect the connectors.
  
  Fig 47: Installing Screw Of Blower Connector Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INSTRUMENT PANEL REINFORCEMENT
1. Install the instrument panel reinforcement with the 7 bolts and 3 caps.
  
  Fig 48: Installing Bolts Of Instrument Panel Reinforcement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 earth wires with the 3 nuts.
  
  Fig 49: Installing Earth Wires With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 7 clamps, connect the wire harness.
  
  Fig 50: Installing Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STEERING COLUMN ASSY
1. Install the steering column assy with the 3 bolts.
2. Install the 2 clamps.
  
  Fig 51: Installing Bolts Of Steering Column Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the steering side connector block with the 2 nuts.
  Torque: 8.4 N.m (85 kgf deg; Cm, 73 in..lbf)
  
  Fig 52: Installing Nut Of 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 deg; Cm, 73 in..lbf)
  
  Fig 53: Installing Nuts Of Driver Side Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 54: Installing Nuts Of Instrument Panel Brace Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the nut and clamp.
  
  Fig 55: Installing Nut And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the earth wire with the bolt.
  
  Fig 56: Installing Earth Wire With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the passenger side junction block with the nut and clamp.
  Torque: 8.4 N.m (85 kgf deg; Cm, 73 in..lbf)
  
  Fig 57: Installing Bolts Of Passenger Side Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INSTRUMENT FINISH PANEL RETAINER LOWER
1. Install the instrument finish panel retainer lower with the 2 bolts.
  
  Fig 58: Installing Bolts Of Instrument Finish Panel Retainer Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1
1. Install the instrument panel brace sub-assy No. 1 with the nut.
2. Install the bolt and screw.
  Torque: 9.8 N.m (100 kgf deg; Cm, 87 in..lbf) (Screw)
  
  Fig 59: Installing Bolt And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 clamps.
  
  Fig 60: Installing Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 earth wires with the 2 bolts.
  
  Fig 61: Installing Earth Wires With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See INSTRUMENT PANEL/METER )
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 62: Installing Cooler Refrigerant Suction Hose And Piping Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER REFRIGERANT LIQUID PIPE A
HINT:

Install in the same way as the cooler refrigerant suction hose No. 1.
ADD COOLANT
3MZ-FE: (See COOLANT (1MZ-FE/3MZ-FE) )

1MZ-FE: (See COOLANT (1MZ-FE/3MZ-FE) )

2AZ-FE: (See COOLANT (2AZ-FE) (FROM JULY, 2003) )
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.)
WARM UP ENGINE
CHECK FOR ENGINE COOLANT LEAKS
3MZ-FE: (See COOLANT (1MZ-FE/3MZ-FE) )

1MZ-FE: (See COOLANT (1MZ-FE/3MZ-FE) )

2AZ-FE: (See COOLANT (2AZ-FE) (FROM JULY, 2003) )
INSPECT LEAKAGE OF REFRIGERANT (See REPLACEMENT )