A/C Radiator Assembly Overhaul

Air Conditioning Radiator Assy Part 1:

Air Conditioning Radiator Assy Part 2:

OVERHAUL

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. REMOVE FR WIPER ARM RH
3. REMOVE FR WIPER ARM LH
4. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
7. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
8. REMOVE FRONT SHOCK ABSORBER CAP RH (W/ AIR SUSPENSION)
9. REMOVE FRONT SHOCK ABSORBER CAP LH (W/ AIR SUSPENSION)




10. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Remove the clamp and disconnect the rubber grommet.
b. Remove the 4 bolts, 6 nuts and cowl top panel sub-assembly outer.

11. DISCONNECT LIQUID TUBE SUB-ASSEMBLY A
a. Install SST(s) on piping clamp.
SST 09870-00025

HINT: Make sure the direction of the piping clamp claw and SST(s) by seeing the illustration shown on the caution label.




b. Push down SST(s) and release the clamp lock.

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

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




d. Disconnect the liquid tube sub-assembly A.

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.

e. Remove the 2 O-rings from the liquid tube sub-assembly A.

12. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1
SST 09870-00015

HINT: Disconnection of the cooler refrigerant suction hose No.1 is same as the liquid tube sub-assembly.




13. DISCONNECT HEATER OUTLET WATER HOSE
a. Using pliers, grip the claws of the clip and slide the clip, and then disconnect the heater outlet water hose.

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

14. DISCONNECT HEATER INLET WATER HOSE

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

15. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY W/PASSENGER AIR BAG ASSEMBLY

HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assembly w/ passenger air bag assembly.

16. REMOVE ECM
17. REMOVE AIRCONDITIONER AMPLIFIER ASSEMBLY




18. REMOVE AIR DUCT REAR NO.2
a. Take up the floor carpet.

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

b. Release the claw fitting and remove the air duct rear No.2.




19. REMOVE AIR DUCT REAR NO.1
a. Take up the floor carpet.

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

b. Release the claw fitting and remove the air duct rear No.1.




20. REMOVE AIR DUCT NO.1
a. Remove the bolt.
b. Release the 3 claw fittings and remove the air duct No.1.

21. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
22. REMOVE SHIFT LEVER ASSEMBLY





23. REMOVE INSTRUMENT PANEL BRACKET NO.4
a. Remove the 4 nuts and instrument panel bracket No.4.




24. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1
a. Remove the clamp and disconnect the connector.
b. Remove the 3 bolts and 2 nuts and instrument panel brace sub-assembly No.1.




25. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2
a. Remove the clamp and disconnect the connector.
b. Remove the 3 bolts and 2 nuts and instrument panel brace sub-assembly No.2.

26. SEPARATE STEERING INTERMEDIATE SHAFT SUB ASSEMBLY

27. REMOVE STEERING COLUMN ASSEMBLY




28. REMOVE AIR DUCT SUB-ASSEMBLY NO.1
a. Remove the 3 nuts and air duct sub-assembly No.1.




29. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Remove the 4 bolts and 4 nuts.




b. Remove the clamp.
c. Disconnect the connectors.
d. Remove the 9 bolts and the 2 nuts and then remove the instrument panel reinforcement while holding the air conditioner unit assembly

HINT: Make sure to keep the air conditioner unit assembly unmoved as the installation parts of the bracket in the air conditioner unit assembly could be damaged.




30. REMOVE AIR CONDITIONER UNIT ASSEMBLY
a. Remove the 2 nuts and air conditioner unit assembly.

HINT: Make sure to keep the air conditioner unit assembly unmoved as the installation parts of the bracket in the air conditioner unit assembly could be damaged.




31. REMOVE AIR DUCT NO.2
a. Remove the screw.
b. Release the 2 claw fittings and remove the air duct No.2.




32. REMOVE WIRING AIR INDICATOR HARNESS SUB-ASSEMBLY NO.2
a. Remove the 3 screws.
b. Remove the clamp and disconnect the 2 connectors.




33. REMOVE BLOWER ASSEMBLY
a. Remove the screw.
b. Release the claw fitting and remove the blower assembly.




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




35. REMOVE MODE DAMPER SERVO SUB-ASSEMBLY
a. Remove the 3 screws and mode damper servo sub-assembly.




36. REMOVE AIRMIX DAMPER SERVO SUB-ASSEMBLY
a. LH side:
Remove the 3 screws and air mix damper servo sub-assembly.




b. RH side:
Remove the 3 screws and air mix damper servo sub-assembly.




37. REMOVE COOLER THERMISTOR NO.1
a. Release the clamp and connector.
b. Release the 2 claws fittings and remove cooler thermistor No.1.




38. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the 2 screws and piping cover.




b. Remove the screw and bracket.




c. Remove the heater radiator unit sub-assembly.

NOTE: Prepare a drain pan or cloth for when the cooling water leaks.




39. REMOVE AIR CONDITIONING TUBE ASSEMBLY
a. Remove the packing.




b. Using a hexagon wrench 4.0 mm (0.15 in.), remove the 2 hexagon bolts and air conditioning tube assembly.
c. Remove the 2 O-rings from the air conditioning tube assembly.




40. REMOVE COOLER EXPANSION VALVE
a. Remove the cooler expansion valve from the cooler evaporator sub-assembly No.1.




41. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Remove the 3 screws and air duct sub-assembly.




b. Release the 4 claw fittings and remove the air duct sub-assembly.




c. Remove the 11 screws and separate the heater case.
d. Remove the cooler evaporator sub-assembly No.1.




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




42. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO.1
a. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the cooler expansion valve.
Compressor oil: ND-OIL8 or equivalent
b. Install the 2 O-rings on the cooler evaporator sub-assembly No.1.




c. Install the cooler evaporator sub-assembly No.1 to the heater case.
d. Install the heater case with the 11 screws.




e. Install the air duct sub-assembly with the 4 claws.




f. Install the air duct sub-assembly with the 3 screws.




43. INSTALL COOLER EXPANSION VALVE
a. Install the cooler expansion valve to the cooler evaporator sub-assembly No.1.




44. INSTALL AIR CONDITIONING TUBE ASSEMBLY
a. Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the air conditioning tube assembly.
Compressor oil: ND-OIL8 or equivalent
b. Install the 2 O-rings on the air conditioning tube assembly.
c. Using a hexagon wrench 4.0 mm (0.15 in.), install the air conditioning tube assembly with the 2 hexagon bolts.

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




d. Install the packing.

NOTE:
- Be sure to install the packing securely so that there is no clearance.
- Wrap the packing as shown in the illustration to keep out moisture.




45. INSTALL AIR DUCT NO.2
a. Install the air duct No.2 with the screw.

Torque: 2.5 Nm (25 kgf.cm, 22 in.lbf)




46. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY
a. Temporarily tighten the air conditioner unit assembly with the 2 nuts.

HINT: Make sure to keep the air conditioner unit assembly unmoved as the installation parts of the bracket in the air conditioner unit assembly could be damaged.




47. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Install the instrument panel reinforcement with the 8 bolts.

Torque: 20 Nm (204 kgf.cm, 15 ft.lbf)




b. Temporarily tighten the air conditioner unit assembly with the 2 nuts and bolt.
c. Install the 4 bolts and 4 nuts.




d. Install the clamps.
e. Connect the connectors.




48. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2
a. Install the instrument panel brace sub-assembly No.2 with the 3 bolts and 2 nuts.
b. Install the clamps and connect the connectors.




49. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1
a. Install the instrument panel brace sub-assembly No.1 with the 3 bolts and 2 nuts.
b. Install the clamps and connect the connectors.




50. INSTALL AIR DUCT SUB-ASSEMBLY NO.1
a. Install the air duct sub-assembly No.1 with the 3 nuts.

Torque: 9.8 Nm (100 kgf.cm, 87 in.lbf)

NOTE: Tighten the bolts in numerical order shown in the illustration to install the air duct sub-assembly No.1.




51. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY
a. Fully tighten the air conditioner unit assembly with the 3 bolts and 4 nuts.

Torque: 9.8 Nm (100 kgf.cm, 87 in.lbf)

NOTE:
- Tighten the bolts in numerical order shown in the illustration to install the air conditioner unit assembly.
- Install the air conditioner unit assembly so that there is no clearance between the duct and blower assembly.




52. INSTALL AIR DUCT NO.1
a. Install the air duct No.1 with the bolt.

Torque: 9.8 Nm (100 kgf.cm, 87 in.lbf)

53. INSTALL STEERING COLUMN ASSEMBLY
MANUAL TILT:
POWER TILT & TELESCOPIC:
54. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
MANUAL TILT:
POWER TILT & TELESCOPIC:
55. INSTALL ECM
56. INSTALL SHIFT LEVER ASSEMBLY
57. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
58. INSPECT SHIFT LEVER POSITION
59. ADJUST SHIFT LEVER POSITION
60. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY W/PASSENGER AIR BAG ASSEMBLY




61. 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 for claw of the piping clamp.

62. INSTALL LIQUID TUBE SUB-ASSEMBLY A
a. Remove the attached vinyl tape from the hose.
b. Coat a new O-ring with compressor oil and install it to the pipe.
Compressor oil: ND-OIL 8 or equivalent
c. Install the liquid tube sub-assembly A and piping clamp.

HINT:
- Be sure to connect the hose securely.
- After connection, check the fitting for claw of the piping clamp.




63. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Install the cowl top panel sub-assembly outer with the 4 bolts and 6 nuts.

Torque: 80 Nm (816 kgf.cm, 59 ft.lbf) (NUT A)

64. INSTALL FRONT SHOCK ABSORBER CAP LH (W/ AIR SUSPENSION)
65. INSTALL FRONT SHOCK ABSORBER CAP RH (W/ AIR SUSPENSION)
66. ADD ENGINE COOLANT
67. CHARGE REFRIGERANT
SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

Specified amount: 600 ± 50 g (21.15 ± 1.76 oz.)

68. WARM UP ENGINE
69. CHECK FOR ENGINE COOLANT LEAKS
70. INSPECT LEAKAGE OF REFRIGERANT