Cooling Unit Toyota MR2 W30

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1. REMOVE GLOVE COMPARTMENT DOOR
2. INSPECT FOR LEAKAGE OF REFRIGERANT Remove the nut, screw and No.1 instrument panel lower bracket. Remove the blower resistor. Disconnect the blower resistor connector. Remove the 2 screws and blower resistor. Inspect for the leakage of refrigerant, using a gas leak detector. If there is leakage, check the tightening torque at the joints or check the evaporator (See «INSPECTION»(/toyota/mr2/w30-1999-2007/remont/manual-hvac-system/#cooling-unit__inspection) and «REASSEMBLY»(/toyota/mr2/w30-1999-2007/remont/manual-hvac-system/#cooling-unit) ). Reinstall the blower resistor with the 2 screws. Reconnect the blower resistor connector. Reinstall the No.1 instrument panel lower bracket with the nut and screw.
3. INSPECT EXPANSION VALVE Check the quantity of gas during refrigeration cycle. Set on the manifold gauge set. Run the engine. Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is 1.37 - 1.57 MPa (14-16 kgf/cm 2 , 199 - 228 psi). Check the expansion valve. If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm 2 , 0 psi). HINT: When the low pressure drops to 0 kPa (0 kgf/cm 2 , 0 psi), feel the receiver's IN and OUT sides for zero temperature difference.
4. INSPECT THERMISTOR RESISTANCE Disconnect the thermistor connector. Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 1,700 ohm at 25°C (77°F) If resistance is not as specified, replace the thermistor.
5. REINSTALL GLOVE COMPARTMENT DOOR

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1. REMOVE LUGGAGE COMPARTMENT TRIM BOX COVER
2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
3. DISCONNECT LIQUID TUBE AND SUCTION HOSE Using SST, remove the 2 piping clamps. SST 09870-00015 (Suction tube) 09870-00025 (Liquid tube) Insert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST using the illustration shown on the caution label. Push down SST and release the clamp lock. NOTE: Be careful not to deform the tubes, when pushing SST. Pull SST slightly and push the release lever, then remove the piping clamp with SST. Remove the piping clamp from SST. Disconnect the both tubes. NOTE: Do not use tools like screwdrivers to remove the tube. Cap the open fittings immediately to keep moisture or dirt out of the system.
4. REMOVE GLOVE COMPARTMENT DOOR
5. REMOVE COOLING UNIT Remove the screw, nut and No. 1 instrument panel lower bracket. Cut off the instrument panel as shown in the illustration. HINT: After cutting off the instrument panel, file the cutting face and smooth the surface. Disconnect the blower resistor connector. Disconnect the thermistor connector. Remove the 4 screws, 2 nuts and cooling unit.

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1. REMOVE THERMISTOR Disconnect the connector clamp. Using a screwdriver, pull out the thermistor. HINT: Tape the screwdriver tip before use. Release the 2 claw and remove the thermistor from the bracket plate.
2. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor.
3. SEPARATE UPPER AND LOWER UNIT CASE Using a knife, cut off each packing. Remove the 6 screws holding the upper to the lower unit case. Separate the upper and lower unit case.
4. REMOVE EVAPORATOR Remove the evaporator from the lower unit case.
5. REMOVE EXPANSION VALVE Using a 5 mm hexagon wrench, remove the 2 bolts, and separate the expansion valve and evaporator.

INSPECTION

1. INSPECT EVAPORATOR Check evaporator fins for blockage. If the fins are clogged, clean them with compressed air. NOTE: Never use water to clean the evaporator. Check fitting for cracks or scratches. If necessary, repair or replace.
2. INSPECT THERMISTOR (See INSPECTION )
3. INSPECT BLOWER RESISTOR (See INSPECTION )
4. INSPECT EXPANSION VALVE (See «ON-VEHICLE INSPECTION»(/toyota/mr2/w30-1999-2007/remont/manual-hvac-system/#cooling-unit) )

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1. INSTALL EXPANSION VALVE Coat 4 new O-rings with compressor oil. Using a 5 mm hexagon wrench, install the expansion valve to the evaporator with the 2 bolts. Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)
2. INSTALL EVAPORATOR Install the evaporator to the lower case unit. If evaporator was replaced, add compressor oil to the compressor. Add 40 cc (1.4 fl. oz.) Compressor oil: ND-OIL 8 or equivalent
3. ASSEMBLE UPPER AND LOWER UNIT CASES Assemble the upper and lower unit cases. Install the 6 screws.
4. INSTALL BLOWER RESISTER Install the blower resister with the 2 screws.
5. INSTALL THERMISTOR Install the thermistor to the bracket plate. Push into the thermistor to the cooling unit. Connect the connector clamp.

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1. INSTALL COOLING UNIT Install the cooling unit with the 4 screws and 2 nuts. Connect the thermistor connector. Connect the blower resister connector. Install the glove compartment door reinforcement (supply part) and No. 1 instrument panel lower bracket with the 2 screws and nut. HINT: Install the glove compartment door reinforcement with the bent side facing to the driver seat side. Pile up the glove compartment door reinforcement (supply part) on the No. 1 instrument panel lower bracket.
2. INSTALL GLOVE COMPARTMENT DOOR
3. CONNECT LIQUID TUBE AND SUCTION TUBE Connect the both tubes. Install the 2 piping clamps. After connection, check the fitting for claw of the piping clamp.
4. CHARGE REFRIGERANT TO REFRIGERATION SYSTEM Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 500 +/- 30 g (17.64 +/- 1.06 oz.)
5. INSTALL LUGGAGE COMPARTMENT TRIM BOX COVER

See also:
• INSPECTION
• REASSEMBLY