Air Conditioning Radiator ASSY: Overhaul

HINT:

See COMPONENTS 

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  COMPONENTS  ) 

   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 shown 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: Removing Piping Clamp With SST

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   4. Disconnect the cooler refrigerant suction hose No. 1.
      NOTE:

      • Do not use tools like a 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 MOTOR SALES, U.S.A., INC.
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 MOTOR SALES, U.S.A., INC.
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  COMPONENTS  ) 

   HINT:

   Refer to the instructions for removal of the 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 Screws, Bolt And Nut

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
8. 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 Air Duct Rear No. 2 Screws, Bolt And Nut

      Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. REMOVE CONSOLE BOX DUCT NO. 1 (AUTO AIR CONDITIONING) 
   1. Remove the clip and console box duct No. 1.
   Fig 6: Removing Clip And Console Box Duct No. 1
   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
10. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY 
11. REMOVE WINDSHIELD WIPER RELAY ASSY 
12. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 1 
    1. Remove the 2 bolts and 2 earth wires.
       Fig 7: Removing Bolts And Earth Wires

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Release the 2 clamps.
       Fig 8: Removing Clamps

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    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 Bolt, Screw And Nut

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13. REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER 
    1. Remove the 2 bolts and instrument finish retainer lower.
    Fig 10: Removing Instrument Finish Retainer Lower Bolts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
14. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO. 2 
    1. Remove the clamp, nut and passenger side junction block.
       Fig 11: Removing Passenger Side Junction Block Clamp And Nut

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Remove the bolt and earth wire.
       Fig 12: Removing Bolt And Earth Wire

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Remove the nut and clamp.
       Fig 13: Removing Nut And Clamp

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Remove the 2 nuts, bolt and instrument panel brace sub-assy No. 2.
    Fig 14: Removing Instrument Panel Brace Sub-Assy No. 2 Nuts And Bolts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
15. REMOVE HEATER TO FOOT DUCT NO. 3 
    1. Remove the clip and heater to foot duct No. 3.
    Fig 15: Removing Clip And Heater To Foot Duct No. 3

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
16. REMOVE HEATER TO FOOT DUCT NO. 1 
    1. Remove the clip and heater to foot duct No. 1.
    Fig 16: Removing Clip And Heater To Foot Duct No. 1

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
17. DISCONNECT STEERING COLUMN ASSY 
    1. Remove the 3 nuts and driver side junction block.
       Fig 17: Removing Driver Side Junction Block Nuts

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Remove the 2 nuts and steering side connector block.
       Fig 18: Removing Steering Side Connector Block Nuts

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Release the 2 clamps.
    4. Remove the 3 bolts, disconnect the steering column assy.
    Fig 19: Removing Steering Column Assy Clamps And Bolts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
18. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Disconnect the 7 clamps and the wire harness.
       Fig 20: Identifying Clamps And Wire Harness

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Remove the 3 nuts, disconnect the 3 earth wires.
       Fig 21: Identifying Nuts And Earth Wires

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Remove the 3 caps, 7 bolts and instrument panel reinforcement.
    Fig 22: Removing Instrument Panel Reinforcement Caps And Bolts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19. REMOVE BLOWER ASSY 
    1. Disconnect the connectors.
    2. Remove the screw, clamp and blower connector holder.
       Fig 23: Removing Screw, Clamp And Blower Connector Holder

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Disconnect the 6 clamps and the wire harness.
       Fig 24: Identifying Clamps And Wire Harness

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Remove the 2 screws, 2 nuts and blower assy.
    Fig 25: Removing Blower Assy Screws And Nuts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
20. REMOVE DEFROSTER NOZZLE ASSY LOWER 
    1. Release the 4 fitting claws, remove the defroster nozzle assy lower.
    Fig 26: Identifying Defroster Nozzle Assy Lower Claws

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
21. REMOVE AIR CONDITIONING RADIATOR ASSY 
    1. Disconnect the connectors.
    2. Remove the 2 nuts and air conditioning radiator assy.
    Fig 27: Removing Air Conditioning Radiator Assy Nuts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
22. REMOVE MODE DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and mode damper servo sub-assy.
    Fig 28: Identifying Mode Damper Servo Sub-Assy Screws

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
23. 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: Identifying Claws And Piping Clamp

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
24. REMOVE AIRMIX DAMPER SERVO SUB-ASSY 
    1. Remove the 3 screws and air mix damper servo sub-assy.
    Fig 30: Identifying Air Mix Damper Servo Sub-Assy Screws

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
25. REMOVE AIR CONDITIONING TUBE ASSY 
    1. Remove the packing.
       Fig 31: Removing Packing

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    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 Hexagon Bolts, Air Conditioning Tube Assy And O-Rings

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
26. 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 MOTOR SALES, U.S.A., INC.
27. REMOVE COOLER THERMISTOR NO. 1 
28. 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: Identifying Air Duct Sub-Assy Claw And Screws

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    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: Identifying Heater Case LH Screws

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Remove the 2 O-rings from the cooler evaporator sub-assy No. 1.
    Fig 36: Removing O-Rings From Cooler Evaporator Sub-Assy No. 1

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
29. 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 O-Rings

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    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: Installing Cooler Evaporator Sub-Assy No. 1 To Heater Case LH

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Auto A/C model:

       Install the air duct sub-assy with the 3 screws.

       Fig 39: Identifying Air Duct Sub-Assy Screws

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
30. 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 No. 1

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
31. 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.
       Fig 41: Installing Air Conditioner Tube Assy, Hexagon Bolts And O-Rings

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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

    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 MOTOR SALES, U.S.A., INC.
32. 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) 

    2. Connect the connector.
    Fig 43: Installing Air Conditioning Radiator Assy Nuts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
33. 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: Identifying Pins (1, 2, 3)

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
34. 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 45: Installing Blower Assy Screws And Nuts

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Install the 6 clamps, connect the wire harness.
       Fig 46: Identifying Wire Harness And Clamps

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Install the blower connector holder with the screw and clamp.
    4. Connect the connectors.
    Fig 47: Installing Blower Connector Holder Screw And Clamp

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
35. INSTALL INSTRUMENT PANEL REINFORCEMENT 
    1. Install the instrument panel reinforcement with the 7 bolts and 3 caps.
       Fig 48: Installing Instrument Panel Reinforcement Bolts And Caps

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Install the 3 earth wires with the 3 nuts.
       Fig 49: Installing Earth Wires And Nuts

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Install the 7 clamps, connect the wire harness.
    Fig 50: Identifying Wire Harness And Clamps

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
36. INSTALL STEERING COLUMN ASSY 
    1. Install the steering column assy with the 3 bolts.
    2. Install the 2 clamps.
       Fig 51: Installing Steering Column Assy Bolts And Clamps

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Install the steering side connector block with the 2 nuts.

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

       Fig 52: Installing Steering Side Connector Block Nuts

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Install the driver side junction block with the 3 nuts.

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

    Fig 53: Installing Driver Side Junction Block Nuts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
37. 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 Instrument Panel Brace Sub-Assy No. 2 Nuts And Bolt

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    2. Install the nut and clamp.
       Fig 55: Installing Nut And Clamp

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Install the earth wire with the bolt.
       Fig 56: Installing Earth Wire With Bolt

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Install the passenger side junction block with the nut and clamp.

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

    Fig 57: Installing Passenger Side Junction Block Nut And Clamp

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
38. INSTALL INSTRUMENT FINISH PANEL RETAINER LOWER 
    1. Install the instrument finish panel retainer lower with the 2 bolts.
       Fig 58: Installing Instrument Finish Panel Retainer Lower Bolts

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
39. 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.cm, 87 in.lbf) (Screw) 

       Fig 59: Installing Instrument Panel Brace Sub-Assy No. 1 Nut, Bolt And Screw

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    3. Install the 2 clamps.
       Fig 60: Installing Clamps

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
    4. Install the 2 earth wires with the 2 bolts.
    Fig 61: Installing Earth Wires And Bolts

    Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
40. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (See  COMPONENTS  ) 
41. 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: Checking Piping Clamp Claw Fitting

       Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
42. INSTALL COOLER REFRIGERANT LIQUID PIPE A 

    HINT:

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

43. ADD COOLANT 

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

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

    2AZ-FE: (See  REPLACEMENT  ) 

44. 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.) 

45. WARM UP ENGINE 
46. CHECK FOR ENGINE COOLANT LEAKS 

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

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

    2AZ-FE: (See step 3 on  REPLACEMENT  ) 

47. INSPECT LEAKAGE OF REFRIGERANT (See  REPLACEMENT  )