Heater Core: Service and Repair
AIR CONDITIONING RADIATOR ASSEMBLYOVERHAUL
1. DRAIN HFC-134A (R134A)
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
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 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
SST 09870-00025
HINT: Disconnect in the same way as the cooler refrigerant suction hose No.1.
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-ASSEMBLY
SST 09950-50012 (09951-05010, 09952-05010, 09953-05020, 09954-05020)
HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assembly.
7. SEPARATE STEERING COLUMN ASSEMBLY
a. Remove the 2 bolts and 2 nuts, disconnect the steering column assembly from the instrument panel reinforcement assembly.
8. SEPARATE FLOOR SHIFT ASSEMBLY
a. Remove the 2 nuts and disconnect the shift cable.
b. Remove the 4 nuts and disconnect transmission floor shift assembly.
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-ASSEMBLY NO.1
a. Disconnect the connector clamp.
b. Remove the 3 bolts, 2 nuts and instrument panel brace sub-assembly No.1.
12. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2
a. Remove the 2 bolts, 2 nuts and instrument panel brace sub-assembly 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 ASSEMBLY
a. Remove the bolt and 2 nuts, disconnect the instrument panel junction block assembly.
16. SEPARATE SKID CONTROL ECU ASSEMBLY
a. Remove the 2 nuts and disconnect the skid control ECU assembly.
17. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Remove the 5 bolts, 4 nuts and instrument reinforcement assembly.
18. REMOVE AIR CONDITIONER UNIT ASSEMBLY
a. Disconnect the connector and clamp.
b. Disconnect the connectors connecting the wiring air indicator harness sub-assembly and vehicle harness.
c. Remove the 3 bolts, 2 nuts and air conditioner unit assembly.
19. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY
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 assembly and the air conditioner radiator assembly and remove the latter assembly.
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-ASSEMBLY
a. Remove the 3 screws and mode damper servo sub-assembly.
23. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSEMBLY
a. Remove the air conditioning harness sub-assembly from the air conditioner radiator assembly.
24. REMOVE AIRMIX DAMPER SERVO SUB-ASSEMBLY
a. Remove the 3 screws and airmix damper servo sub-assembly.
25. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the screw and clamp.
b. Remove the heater radiator unit sub-assembly from the air conditioner radiator assembly.
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-ASSEMBLY NO.2
a. Remove the wiring air indicator harness sub-assembly 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 assembly.
31. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Remove the 11 screws and disassemble the air conditioner radiator assembly.
b. Remove the cooler evaporator sub-assembly No.1 from the air conditioner radiator assembly.
c. Remove the 2 O-rings from the cooler evaporator sub-assembly No.1.
32. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Install the cooler evaporator No.1 to the air conditioner radiator assembly.
b. Reassemble the air conditioner radiator assembly with 11 screws.
33. INSTALL COOLER EXPANSION VALVE
a. Apply compressor oil to the contact surfaces of 2 new O-rings and the air conditioner tube assembly 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 ASSEMBLY
a. Install the air conditioner unit assembly 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 ASSEMBLY
a. Install the instrument panel reinforcement assembly, 5 bolts and 4 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
36. INSTALL SKID CONTROL ECU ASSEMBLY
a. Install the 2 nuts and skid control ECU assembly.
Torque: 5.0 N.m (50 kgf.cm, 43 in.lbf)
37. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY
a. Install the instrument panel junction block assembly, 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-ASSEMBLY NO.2
a. Install the instrument panel brace sub-assembly No.2, 2 bolts and 2 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
40. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1
a. Install the instrument panel brace sub-assembly No.1, 2 bolts and 2 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
41. INSTALL FLOOR SHIFT ASSEMBLY
a. Install the 4 nuts and floor shift assembly.
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 ASSEMBLY
a. Install the steering column assembly, 2 bolts and 2 nuts.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
43. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
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
47. CHECK ENGINE COOLANT LEAK
48. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-78060, 07117-88070, 07117-88080)
Specified amount: 650 ± 50 g (22.93 ± 1.76 oz.)
49. WARM UP ENGINE
50. INSPECT LEAKAGE OF REFRIGERANT