Air Conditioning: Removal & Installation Toyota Avalon XX30 рестайлинг

REMOVAL

HINT

1. Installation is in the reverse order of removal.
2. COMPONENTS for instrument panel safety pad sub-assembly: See «COMPONENTS»(ref-291106-S04662377642008072400000) .

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1. DISCONNECT BATTERY NEGATIVE TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working.
2. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See «REMOVAL»(ref-291123-S34069576942008072400000) )
3. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See «REMOVAL»(ref-291123-S34069576942008072400000) )
4. REMOVE COWL TOP VENTILATOR LOUVER RH (See «REMOVAL»(ref-291123-S34069576942008072400000) )
5. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See «REMOVAL»(ref-291123-S34069576942008072400000) )
6. REMOVE COWL TOP OUTSIDE PANEL FRONT Remove the 4 bolts, 2 nuts and cowl top outside panel front.
7. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Remove the bolt, and slide the hook connector. Disconnect the suction hose sub-assembly. 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 AND ACCESSORY Disconnect the air conditioner tube & accessory. 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) 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 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 «REMOVAL»(ref-291106-S23531924012008072400000) 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 Remove the 3 clips and heater to register duct No. 2.
14. REMOVE HEATER TO REGISTER DUCT ASSEMBLY NO. 6 Disengage the 4 claws and then remove the heater to register duct No. 6.
15. REMOVE CONSOLE BOX DUCT NO. 1 Remove the clip and console box duct No. 1.
16. REMOVE FLOOR CARPET BRACKET LH Release the 2 clamps. Turn back the floor carpet. Remove the 3 clips. Remove the floor carpet bracket LH.
17. REMOVE FLOOR CARPET BRACKET RH Release the 3 clamps. Turn back the floor carpet. Remove the 3 clips. Remove the floor carpet bracket RH.
18. REMOVE AIR DUCT REAR NO. 2 Release the 2 claws and remove the air duct rear No. 2.
19. REMOVE AIR DUCT REAR NO. 1 Release the 2 claws and remove the air duct rear No. 1.
20. REMOVE AIR DUCT SUB-ASSEMBLY NO. 1 (See «REMOVAL»(ref-291118-S32044295912008072400000) )
21. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (See «REMOVAL»(ref-291118-S32044295912008072400000) )
22. REMOVE STEERING COLUMN ASSEMBLY (See «REMOVAL»(ref-291118-S32044295912008072400000) )
23. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY Disconnect each connector and remove each clamp. Disconnect the wire harness. Remove the 6 nuts and 3 bolts. Remove the 3 bolts and nut. Using a "Torx" socket wrench (T40), remove the 5 "Tone" bolts. HINT: The "Torx" bolts on the passenger side can be removed with the collar or for adjustment. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly. Remove the 3 bolts, 2 screws and instrument panel reinforcement assembly.

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1. REMOVE AIR DUCT SUB-ASSEMBLY NO. 2 Release the 2 claws and remove the air duct sub-assembly No. 2 as shown in the illustration.
2. REMOVE BLOWER ASSEMBLY (See «REMOVAL»(ref-291136-S11845692552008072400000) )
3. REMOVE AIR OUTLET CONTROL SERVO MOTOR Disconnect the 2 connectors and remove the air conditioner harness. Remove the 3 screws and then the air outlet control servo motor.
4. REMOVE AIR MIX CONTROL SERVO MOTOR Remove the 2 screws and air mix control servo motor.
5. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY Remove the screw and clamp. Release the 4 claws and remove the clamp. 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.
6. REMOVE COOLER AIR HOSE Remove the cooler air hose with the cooler (room temp, sensor) thermistor. Remove the cooler air hose with the cooler (room temp, sensor) thermistor.
7. REMOVE ASPIRATOR Disengage the 2 claws and then remove the aspirator.

Scheme 211

1. INSTALL ASPIRATOR
2. INSTALL COOLER AIR HOSE
3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
4. INSTALL AIR MIX CONTROL SERVO MOTOR
5. INSTALL AIR OUTLET CONTROL SERVO MOTOR
6. INSTALL BLOWER ASSEMBLY
7. INSTALL AIR DUCT SUB-ASSEMBLY NO. 2

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1. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY Install the conditioner unit assembly to the instrument panel reinforcement assembly with the 2 screws and 3 bolts. Torque: Bolt 9.8 N*m (100 kgf*cm, 87 in.*lbf) NOTE: Tighten the bolts and screws in the order shown in the illustration to install the air conditioner unit assembly. Driver seat: Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "Torx" bolts. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) Passenger seat: 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) Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "Torx" bolts. Torque: 20 N*m (204 kgf*cm, 15 in.*lbf) 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) Connect the connectors and clamps. Install the 6 nuts and 3 bolts.
2. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (See «INSTALLATION»(ref-291118-S22871630342008072400000) )
3. INSTALL STEERING COLUMN ASSEMBLY (See «INSTALLATION»(ref-291118-S22871630342008072400000) )
4. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY (See «INSTALLATION»(ref-291106-S11133170542008072400000) )
5. INSTALL AIR CONDITIONER TUBE AND ACCESSORY Remove the attached vinyl tape from the tube. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube assembly. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the liquid tube sub-assembly. Install the liquid tube sub-assembly.
6. INSTALL SUCTION HOSE SUB-ASSEMBLY Remove the attached vinyl tape from hose. 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 Install the O-ring on the suction hose sub-assembly. Move the hook connector in the direction indicated by the arrow in the illustration. Insert the pipe joint into the fitting hole securely and tighten the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
7. CONNECT BATTERY NEGATIVE TERMINAL
8. PERFORM SYSTEM INITIALIZE Some system need initialization when disconnecting the cable from the negative battery terminal. HINT: See «INITIALIZATION»(ref-291101-S25902095052008072400000)
9. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-291116-S42767661062008072400000) )
10. CHECK FOR ENGINE COOLANT LEAKS (See «REPLACEMENT»(ref-291116-S42767661062008072400000) )
11. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
12. WARM UP ENGINE (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
13. INSPECT FOR REFRIGERANT LEAK (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
14. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See «INSTALLATION»(ref-291123-S33202600392008072400000) )
15. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See «INSTALLATION»(ref-291123-S33202600392008072400000) )
16. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See «INSTALLATION»(ref-291123-S33202600392008072400000) )

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HINT

1. Installation is in the reverse order of removal.
2. COMPONENTS for instrument panel safety pad sub-assembly: See «COMPONENTS»(ref-291106-S04662377642008072400000) .

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1. DISCONNECT BATTERY NEGATIVE TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working.
2. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See «REMOVAL»(ref-291123-S34069576942008072400000) )
3. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See «REMOVAL»(ref-291123-S34069576942008072400000) )
4. REMOVE COWL TOP VENTILATOR LOUVER RH (See «REMOVAL»(ref-291123-S34069576942008072400000) )
5. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See «REMOVAL»(ref-291123-S34069576942008072400000) )
6. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY HINT: See «REMOVAL»(ref-291136-S10533648792008072400000)
7. DISCHARGE FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See «REMOVAL»(ref-291136-S10533648792008072400000) )
9. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY (See «REMOVAL»(ref-291136-S10533648792008072400000) )
10. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (See «REMOVAL»(ref-291136-S10533648792008072400000) )
11. DISCONNECT HEATER WATER INLET HOSE A (See «REMOVAL»(ref-291136-S10533648792008072400000) )
12. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY (See «REMOVAL»(ref-291106-S23531924012008072400000) )
13. REMOVE AIR DUCT SUB-ASSEMBLY NO. 1 (See «REMOVAL»(ref-291118-S32044295912008072400000) )
14. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (See «REMOVAL»(ref-291118-S32044295912008072400000) )
15. REMOVE STEERING COLUMN ASSEMBLY (See «REMOVAL»(ref-291118-S32044295912008072400000) )
16. REMOVE HEATER TO REGISTER DUCT NO. 2 (See «REMOVAL»(ref-291136-S10533648792008072400000) )
17. REMOVE HEATER TO REGISTER DUCT ASSEMBLY NO. 6 (See «REMOVAL»(ref-291136-S10533648792008072400000) )
18. REMOVE CONSOLE BOX DUCT NO. 1 (See «REMOVAL»(ref-291136-S10533648792008072400000) )
19. REMOVE FLOOR CARPET BRACKET LH (See «REMOVAL»(ref-291136-S10533648792008072400000) )
20. REMOVE FLOOR CARPET BRACKET RH (See «REMOVAL»(ref-291136-S10533648792008072400000) )
21. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See «REMOVAL»(ref-291136-S10533648792008072400000) )
22. REMOVE AIR DUCT SUB-ASSEMBLY NO. 2 (See «REMOVAL»(ref-291136-S10533648792008072400000) )
23. REMOVE BLOWER ASSEMBLY Remove the connector and clamp, and disconnect the wire harness. Remove the 6 screws and then the blower assembly with the cooler evaporator sub-assembly.

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1. REMOVE EVAPORATOR TEMPERATURE SENSOR Remove the clamp and evaporator temperature sensor.
2. REMOVE COOLER EXPANSION VALVE Using a hexagon wrench 4 mm, remove the 2 hexagon bolts and cooler expansion valve.
3. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY NO. 1 Remove the cooler evaporator sub-assembly No. 1. Remove the 2 O-rings from the cooler evaporator sub-assembly No. 1.
4. REMOVE AIR FILTER COVER PLATE Release the 2 claws and remove the air filter cover plate.
5. REMOVE CLEAN AIR FILTER Remove the clean air filter.
6. REMOVE AIR INLET SERVO MOTOR Remove the 3 screws and air inlet servo motor.
7. REMOVE AIR DUCT SUB-ASSEMBLY NO. 3 Disengage the 4 claws and then remove the air duct sub-assembly No. 3.
8. REMOVE COOLING UNIT MOTOR SUB-ASSEMBLY Remove the 3 screws and cooling unit motor sub-assembly w/ fan.

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1. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY NO. 1 sufficiently apply compressor oil (ND-OIL 8) to 2 new O-rings and the fitting surface. Install the 2 O-rings to the cooler evaporator No. 1. Compressor oil: ND-OIL 8 or equivalent
2. INSTALL COOLER EXPANSION VALVE Using a hexagon wrench 4 mm, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf)
3. INSTALL EVAPORATOR TEMPERATURE SENSOR If using a mew evaporator: Install the sensor to the evaporator as shown in the illustration. If reusing the evaporator: Install the sensor to the evaporator as shown in the illustration. HINT: Completely cover the tube with the grommet.

INSTALLATION

1. INSTALL BLOWER ASSEMBLY Install the blower assembly with the 6 screws.
2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See «REASSEMBLY»(ref-291136-S13260483672008072400000) )
3. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (See «INSTALLATION»(ref-291118-S22871630342008072400000) )
4. INSTALL STEERING COLUMN ASSEMBLY (See «INSTALLATION»(ref-291118-S22871630342008072400000) )
5. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY (See «INSTALLATION»(ref-291106-S11133170542008072400000) )
6. INSTALL AIR CONDITIONER TUBE AND ACCESSORY (See «INSTALLATION»(ref-291136-S17279274262008072400000) )
7. INSTALL SUCTION HOSE SUB-ASSEMBLY (See «INSTALLATION»(ref-291136-S17279274262008072400000) )
8. CONNECT BATTERY NEGATIVE TERMINAL
9. PERFORM SYSTEM INITIALIZE Some systems need initialization when disconnecting the cable from the negative battery terminal. HINT: See «INITIALIZATION»(ref-291101-S25902095052008072400000)
10. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-291116-S42767661062008072400000) )
11. CHECK FOR ENGINE COOLANT LEAKS (See «REPLACEMENT»(ref-291116-S42767661062008072400000) )
12. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
13. WARM UP ENGINE (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
14. INSPECT FOR REFRIGERANT LEAK (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
15. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See «INSTALLATION»(ref-291123-S33202600392008072400000) )
16. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See «INSTALLATION»(ref-291123-S33202600392008072400000) )
17. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See «INSTALLATION»(ref-291123-S33202600392008072400000) )

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1. INSPECT BLOWER MOTOR Remove the blower motor. Disconnect the connector from the cooling unit motor sub-assembly w/ fan. Connect the positive (+) lead to terminal 2 of the blower motor connector, and the negative (-) lead to terminal 1.

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE V-BANK COVER SUB-ASSEMBLY
5. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-291113-S32409717822008072400000) )
6. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(ref-291125-S38874623222008072400000) )
7. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO. 1 Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1. Remove the O-ring from the cooler refrigerant discharge hose No. 1. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Remove the bolt and disconnect the suction hose sub-assembly. Remove the O-ring from the suction hose No. 1. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
9. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector. Remove the 4 bolts and compressor and magnetic clutch.

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1. REMOVE MAGNETIC CLUTCH ASSEMBLY Remove the bolt and bracket. Place the compressor and magnetic clutch in a vise. Using vise pliers, hold the magnet clutch hub. Remove the bolt, magnetic clutch hub and magnetic clutch washer. Using a snap ring expander, remove the snap ring and magnetic clutch rotor. Disconnect the connector. Using a snap ring expander, remove the snap ring and magnetic clutch stator.

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1. INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the magnetic clutch hub. Connect the battery positive lead to terminal 3 of the magnetic clutch connector and the negative lead to the earth wire. Turn on and off the magnetic clutch and measure the clearance. Standard clearance: 0.26 to 0.60 mm (0.010 to 0.024 in.) If the measured value is out of the standard range, remove the magnetic clutch hub and adjust it with the magnetic clutch washers. NOTE: Adjustment shall be performed with 3 or less magnetic clutch washers. Remove the compressor and magnetic clutch from the vise.
2. INSPECT COMPRESSOR OIL Gradually discharge the refrigerant gas from the service valve when replacing the compressor and magnetic clutch with a new one. Drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside the new compressor and magnetic clutch: 130 +15 cc (4.6 + 0.51 fl.oz.) -(Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed before installation) NOTE: When checking the compressor oil level, observe the precautions on the cooler removal / installation. Because compressor oil remains in the pipes of the vehicle, if anew compressor and magnetic clutch is installed without removing some oil, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. If the remaining oil the removed compressor and magnetic clutch is too small in volume, check for oil leakage. Be sure to use ND-OIL8 for compressor oil.
3. INSPECT W/MAGNET CLUTCH COMPRESSOR ASSEMBLY Disconnect the connector from the w/ magnet clutch compressor assembly. Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION SPECIFIED CONDITION Tester connection Condition Specified condition B8-3 - Body Ground Always Below 1 ohms If the resistance is not as specified, replace the w/ magnet clutch compressor assembly.

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1. INSTALL MAGNETIC CLUTCH ASSEMBLY Matching the parts shown in the illustration, install the magnetic clutch stator. Using a snap ring expander, install a new snap ring with the chamfered side facing up. Connect the connector. Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up. Install the magnetic clutch washer and magnetic clutch hub. NOTE: Do not change the combination of the magnetic clutch washer used before disassembly. Using vise pliers, hold the magnetic clutch hub and install the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)

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1. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Install the compressor and magnetic clutch with the 4 bolts. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch. Connect the connector.
2. INSTALL SUCTION HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent Install the O-ring to the suction hose sub-assembly. Install the suction hose sub-assembly to the compressor and magnetic clutch with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
3. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent Install the O-ring to the cooler refrigerant discharge hose No. 1. Install the cooler refrigerant discharge hose No. 1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
4. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-291125-S41892284252008072400000) )
5. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-291113-S24888097202008072400000) )
6. INSTALL V-BANK COVER SUB-ASSEMBLY
7. INSTALL FRONT FENDER APRON SEAL RH
8. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
9. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
10. WARM UP ENGINE (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
11. INSPECT FOR REFRIGERANT LEAK (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )

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HINT

1. Installation is in the reverse order of removal.

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
2. REMOVE AIR CLEANER INLET NO. 2 (See «REMOVAL»(ref-291113-S23697303492008072400000) )
3. REMOVE AIR CLEANER INLET NO. 1 (See «REMOVAL»(ref-291113-S23697303492008072400000) )
4. DISCONNECT HOOD LOCK ASSEMBLY
5. REMOVE RADIATOR SUPPORT UPPER (See «REMOVAL»(ref-291116-S37435631092008072400000) )
6. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO. 1 Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1 from the cooler condenser assembly. Remove the O-ring from the cooler refrigerant discharge hose No. 1. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
7. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY Remove the bolt and disconnect the air conditioner tube & accessory from the cooler condenser assembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
8. REMOVE COOLER CONDENSER ASSEMBLY Remove the 4 bolts and cooler condenser assembly.

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1. INSTALL COOLER CONDENSER ASSEMBLY Install the cooler condenser assembly with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) HINT: If the condenser is replaced with a new one, add compressor oil to the new condenser. Capacity: 40 cc (1.4 fl. oz.) Compressor oil: ND-8 or equivalent
2. INSTALL AIR CONDITIONER TUBE AND ACCESSORY Remove the attached vinyl tape from the tube and the connecting part of the cooler condenser assembly. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the air conditioning tube assembly. Install the air conditioner tube & accessory on the cooler condenser assembly with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
3. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO. 1 Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the cooler refrigerant discharge hose No. 1. Install the cooler refrigerant discharge hose No. 1. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
4. INSTALL RADIATOR SUPPORT UPPER (See «REMOVAL»(ref-291116-S37435631092008072400000) )
5. INSTALL HOOD LOCK ASSEMBLY
6. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
7. WARM UP ENGINE (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )
8. INSPECT FOR REFRIGERANT LEAK (See «REPLACEMENT»(ref-291136-S30846161892008072400000) )

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1. INSPECT A/C ROOM TEMPERATURE SENSOR Remove the A/C room temperature sensor. Disconnect the connector from the A/C room temperature sensor. Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION SPECIFIED CONDITION Tester connection Condition Specified condition 1 - 2 10°C (50°F) 3.00 to 3.73 kohms 1 - 2 15°C (59°F) 2.45 to 2.88 kohms 1 - 2 20°C (68°F) 1.95 to 2.30 kohms 1 - 2 25°C (77°F) 1.60 to 1.80 kohms 1 - 2 30°C (86°F) 1.28 to 1.47 kohms 1 - 2 35°C (95°F) 1.00 to 1.22 kohms 1 - 2 40°C(104°F) 0.80 to 1.00 kohms 1 - 2 45°C (113°F) 0.65 to 0.85 kohms 1 - 2 50°C (122°F) 0.50 to 0.70 kohms 1 - 2 55°C (131°F) 0.44 to 0.60 kohms 1 - 2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (See the graph above). If the resistance value is not as specified, replace the sensor.

Scheme 253

Scheme 254

1. INSPECT A/C ROOM TEMPERATURE SENSOR Remove the A/C room temperature sensor. Disconnect the connector from the A/C room temperature sensor. Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION SPECIFIED CONDITION Tester connection Condition Specified condition 1 - 2 10°C (50°F) 3.00 to 3.73 kohms 1 - 2 15°C (59°F) 2.45 to 2.88 kohms 1 - 2 20°C (68°F) 1.95 to 2.30 kohms 1 - 2 25°C (77°F) 1.60 to 1.80 kohms 1 - 2 30°C (86°F) 1.28 to 1.47 kohms 1 - 2 35°C (95°F) 1.00 to 1.22 kohms 1 - 2 40°C (104°F) 0.80 to 1.00 kohms 1 - 2 45°C (113°F) 0.65 to 0.85 kohms 1 - 2 50°C (122°F) 0.50 to 0.70 kohms 1 - 2 55°C (131°F) 0.44 to 0.60 kohms 1 - 2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (See the graph above). If the resistance value is not as specified, replace the sensor.

Scheme 255

Scheme 256

1. INSPECT A/C EVAPORATOR TEMPERATURE SENSOR Remove the A/C evaporator temperature sensor (A/ C thermistor). Disconnect the connector from the A/C evaporator temperature sensor (A/C thermistor). Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION SPECIFIED CONDITION Tester connection Condition Specified condition 1 - 2 -10°C (14°F) 7.30 to 9.10 kohms 1 - 2 -5°C (23°F) 5.65 to 6.95 kohms 1 - 2 0°C (32°F) 4.40 to 5.35 kohms 1 - 2 5°C (41°F) 3.40 to 4.15 kohms 1 - 2 10°C (50°F) 2.70 to 3.25 kohms 1 - 2 15°C (59°F) 2.14 to 2.58 kohms 1 - 2 20°C (68°F) 1.71 to 2.05 kohms 1 - 2 25°C (77°F) 1.38 to 1.64 kohms 1 - 2 30°C (86°F) 1.11 to 1.32 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (See the graph above). If the resistance value is not as specified, replace the sensor.

Scheme 257

1. INSPECT A/C PRESSURE SENSOR Start the engine. Operate the air conditioning system. Disconnect the connector from A/C pressure sensor. Install the manifold gauge set (See «REFRIGERANT»(ref-291136-S36844541122008072400000) ). Connect the positive (+) lead from the three 1.5 V dry cell batteries to terminal 3 and negative (-) lead to terminal 1. Check the voltage between terminals 2 and 1 of A/C pressure sensor. Voltage: The voltage depends on the refrigerant pressure as shown in the chart. If the voltage is not as specified, replace the sensor.

Scheme 258

HINT

Installation is in the reverse order of removal.

Scheme 259

1. DISCONNECT BATTERY NEGATIVE TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working.
2. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2 (See «REMOVAL»(ref-291106-S23531924012008072400000) )
3. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-291106-S23531924012008072400000) )
4. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER Release the 8 claws and 5 clips and instrument cluster finish panel sub-assembly center. Disconnect the connector and remove the instrument cluster finish panel sub-assembly center.

Scheme 260

1. REMOVE AIR CONDITIONING CONTROL ASSEMBLY LHD: Release the 4 claws and remove the air conditioning control assembly. RHD: Release the 4 claws and remove the air conditioning control assembly.

Scheme 261

1. INSTALL AIR CONDITIONING CONTROL ASSEMBLY

1. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER
2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
3. INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH NO. 2
4. CONNECT BATTERY NEGATIVE TERMINAL
5. PERFORM SYSTEM INITIALIZE Some systems need initialization when disconnecting the cable from the negative battery terminal. HINT: (See «INITIALIZATION»(ref-291101-S25902095052008072400000) ).

Scheme 262

Scheme 263

HINT

Installation is in the reverse order of removal.

1. DISCONNECT BATTERY NEGATIVE TERMINAL Wait for 90 seconds after disconnecting the cable to prevent the airbag working.
2. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO. 2 (See «REMOVAL»(ref-291106-S23531924012008072400000) )
3. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL RH (See «REMOVAL»(ref-291106-S23531924012008072400000) )
4. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Disconnect the connector. Remove the 2 screws and air conditioning amplifier assembly.

Scheme 264

1. CONNECT BATTERY NEGATIVE TERMINAL
2. PERFORM SYSTEM INITIALIZE Some systems need initialization when disconnecting the cable from the negative battery terminal. HINT: See «INITIALIZATION»(ref-291101-S25902095052008072400000) .