Evaporator Case: Service and Repair

Heater And Air Conditioner:

Heater & Air Conditioner:

OVERHAUL

1. DRAIN HFC-134A (R134A)

2. SEPARATE COOLER REFRIGERANT SUCTION PIPE NO.1
a. 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.

b. Push down the 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, then remove the piping clamp with SST.

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

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.

3. SEPARATE COOLER REFRIGERANT LIQUID PIPE A
a. Disconnect in the same way as the cooler refrigerant suction hose No.1.

SST 09870-00025

4. SEPARATE HEATER OUTLET WATER HOSE
a. Slide the clip and disconnect the heater outlet water hose.

5. SEPARATE HEATER INLET WATER HOSE
a. Slide the clip and disconnect the heater inlet water hose.

6. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY

SST 09950-50013 (09951-05010, 09952-05010, 09953-O5020, 09954-05021)

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

7. SEPARATE STEERING COLUMN ASSY
a. Remove the 2 bolts and 2 nuts, disconnect the steering column assy from the instrument panel reinforcement assy.

8. SEPARATE FLOOR SHIFT ASSY

a. Remove the 2 nuts and disconnect the shift cable.

b. Remove the 4 nuts and disconnect transmission floor shift assy.

9. REMOVE AIR DUCT REAR NO.2
a. Remove the side scuff plate.
b. Remove the floor carpet.

HINT: Turn up the floor carpet to a certain extent so that the air duct rear No.2 can be remove.

c. Remove the air duct rear No.2.

10. REMOVE AIR DUCT REAR NO.1

HINT: Remove it in the same way with the air duct rear No.2.

11. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1
a. Disconnect the connector clamp.
b. Remove the 3 bolts, 2 nuts and instrument panel brace sub-assy No.1.

12. REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2
a. Remove the 2 bolts, 2 nuts and instrument panel brace SUB-Assy No.2.

13. SEPARATE ECM
a. Remove the 2 nuts, disconnect the ECM.

14. SEPARATE MULTIPLEX NETWORK BODY ECU
a. Remove the 2 nuts and multiplex network body ECU.

15. SEPARATE INSTRUMENT PANEL JUNCTION BLOCK ASSY
a. Remove the bolt and 2 nuts, disconnect the instrument panel junction block assy.

16. SEPARATE SKID CONTROL ECU ASSY
a. Remove the 2 nuts and disconnect the skid control ECU assy.

17. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY
a. Remove the 5 bolts, 4 nuts and instrument reinforcement assy.

18. REMOVE AIR CONDITIONER UNIT ASSY

a. Disconnect the connector and clamp.

b. Disconnect the connectors connecting the wiring air indicator harness sub-assy and vehicle harness.
c. Remove the 3 bolts, 2 nuts and air conditioner unit assy.

19. REMOVE AIR CONDITIONING RADIATOR ASSY
a. Remove the screw, disconnect the connected part of the duct and take off the air duct No.2.

b. Remove the 4 screws and bracket.
c. Disconnect the connection between the blower assy and the air conditioner radiator assy and remove the latter assy.

20. REMOVE AIR DUCT NO.1
a. Release the 3 claw fittings, remove the air duct No.1.

21. REMOVE HEATER TO REGISTER DUCT CENTER
a. Release the 4 claw fittings, remove the heater to register duct center.

22. REMOVE MODE DAMPER SERVO SUB-ASSY
a. Remove the 3 screws and mode damper servo sub-assy.

23. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSY
a. Remove the air conditioning harness sub-assy from the air conditioner radiator assy.

24. REMOVE AIR MIX DAMPER SERVO SUB-ASSY
a. Remove the 3 screws and airmix damper servo sub-assy.

25. REMOVE HEATER RADIATOR UNIT SUB-ASSY
a. Remove the screw and clamp.
b. Remove the heater radiator unit sub-assy from the air conditioner radiator assy.

26. REMOVE COOLER THERMISTOR NO.1

27. REMOVE BLOWER MOTOR CONTROL (AUTO AIR CONDITIONER)
a. Remove the 2 screws and blower motor control.

28. REMOVE BLOWER RESISTOR (MANUAL AIR CONDITIONER)
a. Remove the 2 screws and blower resistor.

29. REMOVE WIRING AIR INDICATOR HARNESS SUB-ASSY NO.2
a. Remove the wiring air indicator harness sub-assy No.2 from the blower motor control.

30. REMOVE COOLER EXPANSION VALVE
a. Using a hexagon wrench 4 mm, remove the 2 hexagon bolts and cooler expansion valve.
b. Remove the 2 O-rings from the air conditioner tube assy.

31. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1
a. Remove the 11 screws and disassemble the air conditioner radiator assy.
b. Remove the cooler evaporator sub-assy No.1 from the air conditioner radiator assy.
c. Remove the 2 O-rings from the cooler evaporator sub-assy No.1.

32. INSTALL COOLER EVAPORATOR SUB-ASSY NO.1
a. Install the cooler evaporator No.1 to the air conditioner radiator assy.
b. Reassemble the air conditioner radiator assy with 11 screws.

33. INSTALL COOLER EXPANSION VALVE
a. Apply compressor oil to the contact surfaces of 2 new 0-rings and the air conditioner tube assy and install them.
Compressor oil: ND-OIL 8 or equivalent
b. Using a hexagon wrench 4, install the cooler expansion valve and 2 hexagon bolts to the cooler evaporator No.1.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

34. INSTALL AIR CONDITIONER UNIT ASSY
a. Install the air conditioner unit assy with the 3 bolts and 2 nuts.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
b. Connect the connectors connecting the wiring air indicator No.2 harness and vehicle harness.

c. Install the connector and clamp.

35. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY
a. Install the instrument panel reinforcement assy, 5 bolts and 4 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)

36. INSTALL SKID CONTROL ECU ASSY
a. Install the 2 nuts and skid control ECU assy.
Torque: 5.0 N.m (50 kgf.cm, 43 in.lbf)

37. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY
a. Install the instrument panel junction block assy, bolt and 2 nuts.
Torque: 8.4 N.m (86 kgf.cm, 74 in.lbf)

38. INSTALL ECM
a. Install the ECM and 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

39. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2
a. Install the instrument panel brace sub-assy No.2, 2 bolts and 2 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)

40. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1
a. Install the instrument panel brace sub-assy No.1, 2 bolts and 2 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)

41. INSTALL FLOOR SHIFT ASSY
a. Install the 4 nuts and floor shift assy.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)

b. Install the 2 nuts and shift cable.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)

42. INSTALL STEERING COLUMN ASSY
a. Install the steering column assy, 2 bolts and 2 nuts.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

43. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY

44. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1
a. Lubricate new O-ring with compressor oil and install them to the hose.
Compressor oil: ND-OIL 8 or equivalent

b. Install the cooler refrigerant suction hose No.1 and piping clamp.

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

45. INSTALL COOLER REFRIGERANT LIQUID PIPE A

HINT: Install in the same way as the cooler refrigerant suction pipe No.1.

46. ADD COOLANT

1MZ-FE:
2AZ-FE:

47. CHECK ENGINE COOLANT LEAK

48. CHARGE REFRIGERANT

49. WARM UP ENGINE

50. INSPECT LEAKAGE OF REFRIGERANT