Air Conditioner Unit ASSY: Overhaul

HINT:

• COMPONENT: See AIR CONDITIONER UNIT ASSY .
• Installation is in the reverse order of removal.

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 SUCTION HOSE SUB-ASSY 
   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

      Courtesy 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 Releasing Clamp Lock

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Disconnect the suction hose sub-assy.
   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 Suction Hose Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. DISCONNECT AIR CONDITIONING TUBE ASSY 

   SST 09870-00015

   HINT:

   Disconnect in the same way as the suction hose sub-assy.

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

   Courtesy 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 Sub-Assembly Lower

   Courtesy 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: Taking Up The Floor Carpet

      Courtesy 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 Assembly

      Courtesy 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

   Courtesy 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: Identifying Air Duct No. 1

   Courtesy 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: Identifying Air Duct No. 2

    Courtesy 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: Identifying Air Duct No. 3

    Courtesy 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: Taking Up The Floor Carpet

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 6 fitting claws, remove the air duct rear No. 4.
    Fig 13: Identifying Air Duct No. 4

    Courtesy 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

    Courtesy 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

    Courtesy 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 Assembly

    Courtesy 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-Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. DISCONNECT AIRMIX 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 Airmix Damper Control Cable Sub-Assembly

       Courtesy 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: Removing ECM

    Courtesy 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

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. DISCONNECT STEERING COLUMN ASSY 
    1. Disconnect the connector, remove the 2 clamps.
       Fig 21: Disconnecting Steering Column Connectors & Clamps

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, disconnect the steering column assy.
    Fig 22: Disconnecting Steering Column Assembly

    Courtesy 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 Screws And Earth (Ground) Wires From Instrument Panel Reinforcement

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 6 clamps and wire harness.
       Fig 24: Disconnecting Clamps And Wire Harness

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and instrument panel reinforcement.
    Fig 25: Removing Instrument Panel Reinforcement

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE AIR CONDITIONING 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

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the blower w/fan motor sub-assy.
       Fig 27: Disconnecting Connector From Blower Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector from the damper servo sub-assy.
       Fig 28: Disconnecting Connector From Damper Servo Sub-Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector from the cooler thermistor No. 1.
       Fig 29: Disconnecting The Connector From The Cooler Thermistor No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 nuts, bolt and air conditioner unit assy.
    Fig 30: Removing Air Conditioner Unit Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE AIR FILTER CASE 
    1. Release the 2 fitting claws, remove the air filter case.
    Fig 31: Releasing Air Filter Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE CLEAN 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 Clean Air Filter

    Courtesy 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-Assembly

    Courtesy 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 Fan Motor Sub-Assembly

    Courtesy 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

    Courtesy 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

    Courtesy 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-Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. REMOVE COOLER THERMISTOR NO. 1 
    1. Remove the clamp.
       Fig 38: Removing Cooler Thermistor No. 1 Connector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the fitting claw, remove the 2 screws and heater case.
       Fig 39: Removing Heater Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Release the fitting claw, remove the 5 screws and heater case.
       Fig 40: Opening The Heater Case

       Courtesy 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

    Courtesy 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: Identifying Air Conditioning Tube Assembly

       Courtesy 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 Air Conditioning Tube Assembly

       Courtesy 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 to install the cooler expansion valve.

    Fig 44: Removing Cooler Expansion Valve

    Courtesy 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 & New O-Rings

    Courtesy 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 Assembly

       Courtesy 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 The Packing

    Courtesy 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

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the heater case with the claw and 5 screws.
       Fig 49: Closing-up Heater Case

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the heater case with the claw and 2 screws.
    Fig 50: Installing Heater Case

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. INSTALL CLEAN AIR FILTER 
    1. Install the air filter to the air conditioner unit assy.
    Fig 51: Installing Air Filter

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
39. INSTALL AIR CONDITIONING 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 Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector to the cooler thermistor No. 1.
       Fig 53: Connecting Connector To Cooler Thermistor No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector to the damper servo sub-assy.
       Fig 54: Connecting Connector To Damper Servo Sub-Assembly

       Courtesy 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

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 fitting claws, connect the connector holder.
    Fig 56: Installing Fitting Claws

    Courtesy 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

    Courtesy 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.
    Fig 58: Setting Arm In FACE Position

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

44. INSTALL AIRMIX 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.
    Fig 59: Setting Arm In Max. Cool Position

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    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.

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

    Courtesy 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 AIR CONDITIONING TUBE ASSY 
    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 air conditioning tube assy and piping clamp.

    HINT:

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

    Fig 61: Installing Air Conditioning Tube Assembly

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
50. INSTALL SUCTION HOSE SUB-ASSY 
    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 suction hose sub-assy and piping clamp.

    HINT:

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

51. ADD COOLANT 

    2ZZ-GE (See  ENGINE COOLANT (2ZZ-GE)  ) 

    1ZZ-FE (See  ENGINE COOLANT (1ZZ-FE)  ) 

52. CHECK FOR ENGINE COOLANT LEAKS 

    2ZZ-GE (See  COOLING SYSTEM (2ZZ-GE)  ) 

    1ZZ-FE (See  COOLING SYSTEM (1ZZ-FE)  ) 

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: 480 +/- 30 g (16.9 +/- 1.06 oz.) 

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