Part 2
25. REMOVE AIR CONDITIONING RADIATOR ASSY
a. Remove the drain hose.
b. Disconnect the connectors.
c. Remove the 2 nuts and air conditioning radiator assy.
26. REMOVE MODE DAMPER SERVO SUB-ASSY
a. Remove the 3 screws and air outlet control servomotor (mode damper servo sub-assy).
27. REMOVE HEATER RADIATOR UNIT SUB-ASSY
a. Remove the screw and plate.
b. Release the 2 fitting claws and remove the piping clamp.
c. Remove the heater radiator unit sub-assy.
NOTE: Prepare a drain pan or cloth for when the cooling water leaks.
28. REMOVE AIRMIX DAMPER SERVO SUB-ASSY
a. Remove the 3 screws and airmix control servomotor (air-mix damper servo sub-assy).
29. REMOVE AIR CONDITIONING TUBE ASSY
a. Remove the packing.
NOTE: Be careful not to break the packing as it is to be reused.
b. Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts and air conditioning tube assy.
c. Remove the 2 O-rings from the air conditioning tube assy.
30. REMOVE COOLER EXPANSION VALVE
a. Remove the cooler expansion valve from the cooler evaporator sub-assy No.1.
31. REMOVE COOLER THERMISTOR NO.1
a. Release the 2 fitting claws and remove the evaporator temperature sensor (cooler thermistor No.1).
32. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1
a. Remove the 12 screws and heater case LH.
b. Remove the cooler evaporator sub-assy No.1 from the heater case RH.
c. Remove the 2 O-rings from the cooler evaporator sub-assy No.1.
33. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1
a. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the cooler expansion valve.
Compressor oil: ND-OIL 8 or equivalent
b. Install the 2 O-rings on the cooler evaporator sub-assy No.1.
c. Install the cooler evaporator sub-assy No.1 to the heater case RH.
d. Install the heater case LH with the 12 screws.
34. INSTALL COOLER EXPANSION VALVE
a. Install the cooler expansion valve to the cooler evaporator No.1.
35. INSTALL AIR CONDITIONING TUBE ASSY
a. 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
b. Install the 2 O-rings on the air conditioning tube assy.
c. Using a hexagon wrench 4 mm (0.16 in.), install the air conditioner tube assy with the 2 hexagon bolts.
Torque:3.5 Nm (35 kgf.cm, 30 in.lbf)
d. Install the packing.
HINT: Securely attach so that a gap in the packing will not occur.
36. INSTALL AIR CONDITIONING RADIATOR ASSY
a. Install the air conditioning radiator assy with the 2 nuts.
Torque:1.5 Nm (15 kgf.cm, 12 in.lbf)
b. Connect the connector.
c. Install the drain hose.
37. INSTALL DEFROSTER NOZZLE ASSY LOWER
a. Install the defroster nozzle assy lower.
NOTE: Install the pins in the order as shown in the illustration.
38. INSTALL BLOWER ASSY
a. Install the blower assy with the 2 screws and 2 nuts.
Torque:1.5 Nm (15 kgf.cm, 12 in.lbf) (NUT)
b. Manual A/C model:
Install the clamp and connect the 4 connectors.
c. Auto A/C model:
Install the clamp and connect the 3 connectors.
d. w/stereo component amplifier assy:
Install the 2 wire harness clamps.
e. Install the 5 wire harness clamps.
f. Install the blower connector holder with the screw and clamp.
g. Connect the connectors.
39. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY
a. Install the instrument panel reinforcement with the 7 bolts and 3 caps.
Torque:20 Nm (204 kgf.cm, 15 ft.lbf) (BOLT A)
b. Install the 3 earth wires with the 3 nuts.
c. Install the 7 wire harness clamps.
40. INSTALL STEERING COLUMN ASSY
a. Install the steering column assy with the 3 bolts and 2 nuts.
Torque:21 Nm (210 kgf.cm, 15 ft.lbf)
b. Install the wire harness clamp and 3 connectors.
41. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY
a. Install the instrument panel junction block assy with the 3 nuts.
Torque:8.4 Nm (85 kgf.cm, 73 in.lbf)
42. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2
a. Install the instrument panel brace sub-assy No. 2 with the 2 nuts and bolt.
b. Install the amplifier antenna assy with the nut and clamp.
c. Install the passenger side junction block with the nut and clamp.
Torque:8.4 Nm (85 kgf.cm, 73 in.lbf)
d. Install the earth wire with the bolt.
43. INSTALL INSTRUMENT FINISH PANEL RETAINER LOWER
a. Install the instrument finish panel retainer lower with the 2 bolts.
44. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1
a. Install the instrument panel brace sub-assy No.1 with the nut and bolt.
b. Install the screw.
Torque:9.8 Nm (100 kgf.cm, 87 in.lbf) (Screw)
c. Install the wire harness with the 2 wire harness clamps.
d. Install the connector holder with the nut.
e. Install the 2 earth wires with the 2 bolts.
45. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY
46. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the attached vinyl tape from the hose.
b. Coat a new O-ring with compressor oil and install it to the hose.
Compressor oil: ND-OIL 8 or equivalent
c. Install the cooler refrigerant suction hose No.1 and piping clamp.
HINT:
- Be sure to connect the hose securely.
- After connection, check the fitting claw of the piping clamp.
47. INSTALL COOLER REFRIGERANT LIQUID PIPE A
HINT: Install in the same way as the cooler refrigerant suction hose No.1.
48. ADD ENGINE COOLANT (2AZ-FE ENGINE TYPE)
49. ADD ENGINE COOLANT (3MZ-FE ENGINE TYPE)
50. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
Specified amount: 550 ± 50g (19.39 ± 1.76 oz.)
51. WARM UP ENGINE
52. CHECK FOR ENGINE COOLANT LEAKS (2AZ-FE ENGINE TYPE)
53. CHECK FOR ENGINE COOLANT LEAKS (3MZ-FE ENGINE TYPE)
54. INSPECT LEAKAGE OF REFRIGERANT