Evaporator Case: Service and Repair

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 on the piping clamp.

SST 09870-00025

HINT: Make sure the direction of the piping clamp claw and SST by checking the illustration on the caution label.




b. Push down SST and release the clamp lock.

NOTE: Be careful not to deform the tube when pushing SST.

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




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

NOTE:
- Do not use a screwdriver or similar tool to disconnect the hose.
- Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

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

3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A

SST 09870-00015

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

4. DISCONNECT HEATER WATER INLET HOSE A




a. Using pliers, grip the claws of the clip and slide the clip.
b. Disconnect the heater water inlet hose A.

5. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

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

6. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER W/FRONT PASSENGER AIRBAG ASSEMBLY

HINT: Refer to the instructions for removal of the instrument panel sub-assembly upper w/ front passenger airbag assembly.

7. REMOVE INSTRUMENT PANEL LOWER ASSEMBLY

HINT: Refer to the instructions for removal of the instrument panel lower assembly.

8. REMOVE ECM

9. REMOVE HEATER TO REGISTER DUCT NO.3




a. Remove the 2 clips.
b. Release the 2 claws and remove the heater to register duct No.3.

10. REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER




a. Release the 2 claws and remove the defroster nozzle assembly lower.

11. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER




a. Remove the 2 bolts and instrument panel to cowl brace center.

12. REMOVE INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY




a. Remove the clip and turn the floor carpet back.




b. Disconnect the 4 clamps and separate the wire harness.




c. Remove the bolt and disconnect the earth wire.




d. Disconnect the 2 clamps and separate the wire harness.




e. Disconnect the 2 claws and separate the connector.




f. Remove the 3 bolts, nut, screw and instrument panel to cowl brace sub-assembly.

13. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2




a. Disconnect the 2 clamps and separate the wire harness.
b. Disconnect the clamp and separate the antenna cord sub-assembly.




c. Remove the bolt, nut and instrument panel brace sub-assembly No.2.

14. REMOVE AIR DUCT




a. Remove the connectors from the air duct and disconnect the connector.




b. Remove the screw.
c. Release the 2 claws and remove the air duct.

15. REMOVE BLOWER ASSEMBLY
16. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY




a. Remove the 2 connectors.




b. Remove the 2 nuts and the air conditioning radiator assembly.

17. REMOVE COOLER UNIT DRAIN HOSE NO.1




a. Remove the cooler unit drain hose No.1.

18. REMOVE AIR DUCT




a. Release the 2 claws and remove the air duct.

19. REMOVE AIR OUTLET CONTROL SERVOMOTOR




a. Remove the 3 screws and the air outlet control servomotor.

20. REMOVE AIR MIX CONTROL SERVOMOTOR




a. Remove the 2 screws and the air mix control servomotor.

21. REMOVE HEATER PIPING COVER




a. Release the 3 claws and remove the heater piping cover.

22. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY




a. Release the 3 claws and remove the clamp.




b. Remove the heater radiator unit sub-assembly.

23. REMOVE AIR CONDITIONING TUBE ASSEMBLY




a. Remove the 2 screws.
b. Release the claw and remove the cover.




c. Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and the air conditioning tube assembly.




d. Remove the 2 O-rings from the air conditioning tube assembly.

24. REMOVE COOLER EXPANSION VALVE




a. Remove the cooler expansion valve from the cooler evaporator sub-assembly No.1.

25. REMOVE EVAPORATOR TEMPERATURE SENSOR




a. Remove the 2 screws and the plate.




b. Remove the 7 screws and the cooler evaporator sub-assembly No.1 and evaporator temperature sensor.




c. Remove the evaporator temperature sensor from the cooler evaporator sub-assembly No.1.

26. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO.1




a. Remove the 2 O-rings from the cooler evaporator sub-assembly No.1.

27. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO.1




a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator sub-assembly No.1.

Compressor oil: ND-OIL 8 or equivalent

b. Install the 2 O-rings on the cooler evaporator sub-assembly No.1.

28. INSTALL EVAPORATOR TEMPERATURE SENSOR




a. Install the evaporator temperature sensor as shown in the illustration.




b. Install the cooler evaporator sub-assembly No.1 on the heater case with the 7 screws.




c. Install the plate with the 2 screws.

29. INSTALL COOLER EXPANSION VALVE




a. Install the cooler expansion valve.

30. INSTALL AIR CONDITIONING TUBE ASSEMBLY




a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assembly.

Compressor oil: ND-OIL 8 or equivalent




b. Using a hexagon wrench 4.0 mm (0.15 in.), install the air conditioning tube assembly with the 2 hexagon bolts.

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




c. Install the cover with the claw and 2 screws.

31. TEMPORARILY TIGHTEN AIR CONDITIONING RADIATOR ASSEMBLY




a. Temporarily tighten the air conditioning radiator assembly with the 2 nuts.




b. Connect the 2 connectors.

32. TEMPORARILY TIGHTEN BLOWER ASSEMBLY




a. Install the blower assembly with the claw.




b. Temporarily tighten the blower assembly with the 3 screws and bolt.




c. Connect the 3 connectors.

33. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY




a. Fully tighten the air conditioner unit assembly with the bolt, screw and 2 nuts.

Torque
Bolt and Nut : 9.8 N.m (100 kgf.cm, 87 in.lbf)

NOTE: Tighten in the order indicated in the illustration.

34. INSTALL INSTRUMENT PANEL LOWER ASSEMBLY

HINT: Refer to procedures from instrument panel lower assembly.

35. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER W/FRONT PASSENGER AIRBAG ASSEMBLY

HINT: Refer to procedures from instrument panel sub-assembly upper w/ front passenger airbag assembly.

36. INSTALL COOLER REFRIGERANT LIQUID PIPE A




a. Remove the attached vinyl tape from the pipe.
b. Sufficiently apply compressor oil to new 2 O-rings and the fitting surface of the cooler refrigerant liquid pipe A.

Compressor oil: ND-OIL 8 or equivalent

c. Install the 2 O-rings on the cooler refrigerant liquid pipe A.
d. Install the cooler refrigerant liquid pipe A and piping clamp.

HINT: After the connection, check that the claw of the piping clamp is engaged.

37. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1
a. Remove the attached vinyl tape from the pipe.
b. Sufficiently apply compressor oil to new 2 O-rings and the fitting surface of the cooler refrigerant suction hose No.1.

Compressor oil: ND-OIL 8 or equivalent

c. Install the 2 O-rings on the cooler refrigerant suction hose No.1.
d. Install the cooler refrigerant suction hose No.1 and the piping clamp.

HINT: After the connection, check that the claw of the piping clamp is engaged.

38. ADD ENGINE COOLANT
39. CHARGE REFRIGERANT

SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

Specified amount: 400 ± 30 g (14.1 ± 1.1 oz.)

40. WARM UP ENGINE
41. CHECK FOR ENGINE COOLANT LEAKS
42. CHECK FOR LEAKAGE OF REFRIGERANT