Part 1

Air Conditioning Radiator Assy - Part 1:

OVERHAUL

HINT:
- Installation is in the reverse order of removal.

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1
a. Install SST to the piping clamp.
SST 09870-00015

HINT: Check the direction of the piping clamp claw and SST by referring to the illustration shown on the caution label.




b. Push down on the SST and release the clamp lock.

NOTE: Be careful not to deform the hose when pushing down on the SST.

c. Pull the SST slightly and push the release lever, then remove the piping clamp with the SST.




d. Disconnect the cooler refrigerant suction hose No.1.

NOTE:
- Do not use tools such as a screwdriver to remove the hose.
- Cap the open fittings immediately to keep moisture or dirt out of the system.

e. Remove the 2 O-rings from the cooler refrigerant suction hose No.1.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A
SST 09870-00025

HINT: Disconnection of the cooler refrigerant liquid pipe A is the same as the cooler refrigerant suction hose No.1.




4. DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT) (2AZ-FE ENGINE TYPE)
a. Using pliers, grip the claws of the clip and slide the clip.
Disconnect the heater water outlet hose A (from the heater unit).

NOTE:
- Do not apply any excessive force to the heater water outlet hose.
- Prepare a drain pan or cloth for when the cooling water leaks.

5. DISCONNECT HEATER WATER INLET HOSE A (2AZ-FE ENGINE TYPE)

HINT: Disconnection of the heater water inlet hose A is the same as the heater water outlet hose A.

6. DISCONNECT HEATER OUTLET WATER HOSE (3MZ-FE ENGINE TYPE)

HINT: Disconnection of the heater outlet water hose is the same as the heater water outlet hose A.

7. DISCONNECT HEATER INLET WATER HOSE (3MZ-FE ENGINE TYPE)

HINT: Disconnection of the heater inlet water hose is the same as the heater water outlet hose A.

8. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY

HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assy with passenger air bag assy.




9. REMOVE AIR DUCT REAR NO.1
a. Fold back the floor carpet.

HINT: Fold back the floor carpet so that the air duct rear No.1 can be removed.

b. Remove the 2 screws, bolt and nut.
c. Remove the air duct rear No.1.




10. REMOVE AIR DUCT REAR NO.2
a. Fold back the floor carpet.

HINT: Fold back the floor carpet so that the air duct rear No.2 can be removed.

b. Remove the 2 screws, bolt and nut. c.Remove the air duct rear No.2.




11. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1
a. Remove the 2 bolts and 2 earth wires.




b. Remove the nut and release the connector holder.




c. Disconnect the 2 wire harness clamps.




d. Remove the bolt and screw.
e. Remove the nut and instrument panel brace sub-assy No.1.




12. REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER
a. Remove the 2 bolts and instrument finish panel retainer lower No.1.




13. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2
a. Remove the bolt and earth wire.




b. Remove the nut.
c. Disconnect the passenger side junction block clamp.




d. Remove the nut and amplifier antenna assy clamp.




e. Remove the 2 nuts, bolt and instrument panel brace sub-assy No.2.




14. REMOVE HEATER TO FOOT DUCT NO.3
a. Remove the clip and heater to foot duct No.3.




15. REMOVE HEATER TO FOOT DUCT NO.1
a. Remove the clip and heater to foot duct No.1.




16. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSY
a. Remove the 3 nuts and instrument panel junction block assy.




17. REMOVE INSTRUMENT PANEL BRACKET SUB-ASSY CENTER
a. Remove the nut and instrument panel bracket sub-assy center.




18. DISCONNECT STEERING COLUMN ASSY
a. Release the wire harness clamp and 3 connectors.




b. Remove the bolt and 2 nuts and disconnect the steering column assy.




19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY
a. Disconnect the 7 wire harness clamps from the instrument panel reinforcement assy.




b. Remove the 3 nuts, and disconnect the 3 earth wires from the instrument panel reinforcement assy.




c. Remove the 3 caps, 7 bolts and instrument panel reinforcement.

20. REMOVE STEREO COMPONENT AMPLIFIER ASSY (W/STEREO COMPONENT AMPLIFIER)
21. REMOVE ECM (2AZ-FE ENGINE TYPE)
22. REMOVE ECM (3MZ-FE ENGINE TYPE)




23. REMOVE BLOWER ASSY
a. Disconnect the connectors.
b. Remove the screw.
c. Disconnect the blower connector holder clamp.




d. Disconnect the 5 wire harness clamps.




e. w/stereo component amplifier assy:
Disconnect the 2 wire harness clamps.




f. Manual A/C model:
Disconnect the 4 connectors and remove the clamp.
g. Auto A/C model:
Disconnect the 3 connectors and remove the clamp.




h. Remove the 2 screws, 2 nuts and blower assy.




24. REMOVE DEFROSTER NOZZLE ASSY LOWER
a. Release the 4 fitting claws and remove the defroster nozzle assy lower.