Air Conditioning Radiator Assembly

AIR CONDITIONING RADIATOR ASSEMBLY

OVERHAUL

HINT: Installation is in the reverse order of removal.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Wait for 90 seconds after disconnecting the cable to prevent the airbag working.
2. REMOVE FR WIPER ARM & BLADE ASSEMBLY LH
3. REMOVE FR WIPER ARM & BLADE ASSEMBLY RH
4. REMOVE COWL TOP VENTILATOR LOUVER RH
5. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSEMBLY




6. REMOVE COWL TOP OUTSIDE PANEL FRONT
a. Remove the 4 bolts, 2 nuts and cowl top outside panel front.

7. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

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




8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
a. Remove the bolt, and slide the hook connector.
b. Disconnect the suction hose sub-assembly.
c. Remove the O-ring from the suction hose sub-assembly.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

9. DISCONNECT AIR CONDITIONER TUBE & ACCESSORY
a. Disconnect the air conditioner tube & accessory.
b. Remove the O-ring from the air conditioner tube & accessory.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.




10. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
a. Slide the clip and disconnect the heater water outlet hose A.

NOTE:
- Do not apply excessive force to the heater water outlet hose A.
- Prepare a drain pan or cloth in case the cooling water leaks.

11. DISCONNECT HEATER WATER INLET HOSE A
a. Slide the clip and disconnect the heater water inlet hose A.

NOTE:
- Do not apply excessive force to the heater water inlet hose A.
- Prepare a drain pan or cloth in case the cooling water leaks.

12. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY W/FRONT PASSENGER AIRBAG ASSEMBLY

HINT: Refer to the removal procedures for the instrument panel safety pad sub-assembly w/ front passenger airbag assembly.




13. REMOVE HEATER TO REGISTER DUCT NO.2
a. Remove the 3 clips and heater to register duct No.2.




14. REMOVE HEATER TO REGISTER DUCT ASSEMBLY NO.6
a. Disengage the 4 claws and then remove the heater to register duct No.6




15. REMOVE CONSOLE BOX DUCT NO.1
a. Remove the clip and console box duct No.1.




16. REMOVE FLOOR CARPET BRACKET LH
a. Release the 2 clamps.
b. Turn back the floor carpet.




c. Remove the 3 clips.
d. Remove the floor carpet bracket LH.




17. REMOVE FLOOR CARPET BRACKET RH
a. Release the 3 clamps.
b. Turn back the floor carpet.




c. Remove the 3 clips.
d. Remove the floor carpet bracket RH.




18. REMOVE AIR DUCT REAR NO.2
a. Release the 2 claws and remove the air duct rear No.2.




19. REMOVE AIR DUCT REAR NO.1
a. Release the 2 claws and remove the air duct rear No.1.

20. REMOVE AIR DUCT SUB-ASSEMBLY NO.1
21. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
22. REMOVE STEERING COLUMN ASSEMBLY
23. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Disconnect each connector and remove each clamp. Disconnect the wire harness.




b. Remove the 6 nuts and 3 bolts.
c. Remove the 3 bolts and nut.
d. Using a Torx(R) socket wrench (T40), remove the 5 Torx(R) bolts.

HINT: The Torx(R) bolts on the passenger side can be removed with the collar or for adjustment.




e. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly.




f. Remove the 3 bolts, 2 screws and instrument panel reinforcement assembly.




24. REMOVE AIR DUCT SUB-ASSEMBLY NO.2
a. Release the 2 claws and remove the air duct sub-assembly N0.2 as shown in the illustration.

25. REMOVE BLOWER ASSEMBLY




26. REMOVE AIR OUTLET CONTROL SERVOMOTOR
a. Disconnect the 2 connectors and remove the air conditioner harness.




b. Remove the 3 screws and then the air outlet control servomotor.




27. REMOVE AIR MIX CONTROL SERVOMOTOR
a. Remove the 2 screws and air mix control servomotor.




28. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the screw and clamp.
b. Release the 4 claws and remove the clamp.




c. Remove the heater radiator unit sub-assembly from the air conditioning radiator assembly.

NOTE: Prepare a drain pan or cloth in case the cooling water leaks.




29. REMOVE COOLER AIR HOSE
a. Remove the cooler air hose with the cooler (room temp. sensor) thermistor.
b. Remove the cooler air hose from the cooler (room temp. sensor) thermistor.




30. REMOVE ASPIRATOR
a. Disengage the 2 claws and then remove the aspirator.




31. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 2 screws and 3 bolts.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) (BOLT)

NOTE: Tighten the bolts and screws in the order shown in the illustration to install the air conditioner unit assembly.

b. Driver seat:
1. Using a Torx(R) ,socket wrench (T40), install the instrument panel reinforcement assembly with the 3 Torx(R) bolts.

Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)

c. Passenger seat:
1. Using a hexagon wrench 12 mm, install the instrument panel reinforcement assembly with the 2 bolts.

Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)

2. Using a Torx(R) socket wrench (T40), install the instrument panel reinforcement assembly with the 2 Torx(R) bolts.

Torque: 20 N.m (204 kgf.cm, 15 in.lbf)




d. Install the 3 bolts and nut.

Torque:
NUT: 9.8 N.m (100 kgf.cm, 87 in.lbf)
BOLT A: 20 N.m (204 kgf.cm, 15 ft.lbf)

e. Connect the connectors and clamps.




f. Install the 6 nuts and 3 bolts.

32. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
33. INSTALL STEERING COLUMN ASSEMBLY
34. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY W/FRONT PASSENGER AIRBAG ASSEMBLY

HINT: Refer to the instructions for installation of the instrument panel safety pad sub-assembly w/ front passenger airbag assembly.

35. INSTALL AIR CONDITIONER TUBE & ACCESSORY
a. Remove the attached vinyl tape from the tube.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assembly.

Compressor oil: ND-OIL 8 or equivalent

c. Install the O-ring on the liquid tube sub-assembly.
d. Install the liquid tube sub-assembly.

36. INSTALL SUCTION HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

Compressor oil: ND-OIL 8 or equivalent

c. Install the O-ring on the suction hose sub-assembly.




d. Move the hook connector in the direction indicated by the arrow in the illustration.
e. Insert the pipe joint into the fitting hole securely and tighten the bolt.

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

37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
38. PERFORM INITIALIZATION

NOTE: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected.

Initialize Front Power Seat Control System
a. The power seat ECU must be initialized under any of the following conditions.
- The battery is disconnected.
- The D/C CUT fuse is replaced.
- The power seat switch (power seat ECU) is replaced.
- The power seat assembly is removed from the vehicle.

b. Initialize the power seat ECU as follows.
1. Using the seat switches, fully slide the seat forward, fully recline the seatback forward, and fully raise the seat cushion and headrest.
2. Using the seat switches, fully slide the seat rearward, fully recline the seatback rearward, and fully lower the seat cushion and headrest.

39. ADD ENGINE COOLANT
40. CHECK FOR ENGINE COOLANT LEAKS
41. CHARGE REFRIGERANT

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

Specified amount: 450 to 550 g (15.9 to 19.4 oz.)

42. WARM UP ENGINE
43. CHECK FOR LEAKAGE OF REFRIGERANT
44. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSEMBLY
45. INSTALL FR WIPER ARM & BLADE ASSEMBLY RH
46. INSTALL FR WIPER ARM & BLADE ASSEMBLY LH