Toyota Corolla (2004+). Manual - part 102

 

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Toyota Corolla (2004+). Manual - part 102

 

 

55-20
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
(b) Release the 6 fitting claws, remove the air duct rear No.4.
6 Claws
I32435
13. REMOVE HEATER TO REGISTER DUCT NO.2
(a) Remove the 2 clips and heater to register duct No. 2.
I32441
14. REMOVE HEATER TO REGISTER DUCT NO.1
(a) Remove the 2 clips and heater to register duct No. 1.
I32442
15. REMOVE DEFROSTER NOZZLE ASSY
(a) Release the 3 fitting claws, remove the defroster nozzle
assy.
3 Claws
I32443
16. DISCONNECT DEFROSTER DAMPER CONTROL
CABLE SUB-ASSY
(a) Disconnect the outer cable from the clamp.
(b) Disconnect the inner cable and defroster damper control
cable sub-assy.
NOTICE:
F
Be careful not to bend the cable wire.
F
If the cable wire bends, the heater control & accesso-
Clamp
ry assy operationality becomes worse.
I32526
55-21
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
17. DISCONNECT AIRMIX DAMPER CONTROL CABLE
SUB-ASSY
(a) Disconnect the outer cable from the clamp.
(b) Disconnect the inner cable and air mix damper control
cable sub-assy.
NOTICE:
F
Be careful not to bend the cable wire.
F
If the cable wire bends, the heater control & accesso-
Clamp
I32527
ry assy operationality becomes worse.
18. DISCONNECT ECM
(a) Remove the 2 bolts and disconnect the ECM.
NOTICE:
F
Do not apply excessive force to the connecter of the
ECM.
F
Do not give any impact to the ECM.
I32534
19. REMOVE INSTRUMENT PANEL TO COWL BRACE
CENTER
(a) Remove the 2 nuts and instrument panel to cowl brace
center.
I32446
20. DISCONNECT STEERING COLUMN ASSY
(a) Disconnect the connector, remove the 2 clamps.
2 Clamps
I32444
(b) Remove the 3 bolts, disconnect the steering column assy.
I32445
55-22
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
21. REMOVE INSTRUMENT PANEL REINFORCEMENT
(a) Remove the 8 screws and 2 earth wires from the instru-
ment panel reinforcement.
I32447
(b) Disconnect the 6 clamps and wire harness.
6 Clamps
I32448
55-23
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
(c)
Remove the 6 bolts and instrument panel reinforcement.
I32449
22. REMOVE AIR CONDITIONER UNIT ASSY
(a) Release the 2 fitting claws, disconnect the connector
Lock Point
holder.
HINT:
Release the claw while pressing the lock part in the arrow direc-
tion.
2 Claws
I32485
(b) Disconnect the connector from the blower w/ fan motor
sub-assy.
I32486
(c)
Disconnect the connector from the damper servo sub-
assy.
I32487
55-24
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
(d) Disconnect the connector from the cooler thermistor No.
1.
I32488
(e) Remove the 4 nuts, bolt and air conditioner unit assy.
I32489
23. REMOVE AIR FILTER CASE
(a) Release the 2 fitting claws, remove the air filter case.
2 Claws
I32490
24. REMOVE AIR FILTER
(a) Remove the air filter from the air conditioner unit assy.
HINT:
Removing only the glove compartment door assy makes it pos-
sible and install the air filter.
I32491
25. REMOVE DAMPER SERVO SUB-ASSY
(a) Remove the 2 screws and damper servo sub-assy.
HINT:
Removing only instrument panel sub-assy upper and heater to
register duct No. 1 makes it possible and install the damper ser-
vo sub-assy.
I32492
55-25
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
26. REMOVE BLOWER W/FAN MOTOR SUB-ASSY
(a) Remove the 3 screws and blower w/ fan motor sub-assy.
HINT:
Removing only the ECM makes it possible and install the blower
w/fan motor sub-assy.
I32493
27. REMOVE BLOWER RESISTOR
(a) Disconnect the connector.
(b) Remove the 2 screws and blower resistor.
HINT:
Removing only the ECM makes it possible and install the blower
resistor.
I32494
28. REMOVE HEATER PIPING COVER
(a) Release the 3 fitting claws, remove the heater piping cov-
er.
3 Claws
I32495
29. REMOVE HEATER RADIATOR UNIT SUB-ASSY
(a) Release the 3 fitting claws, remove the heater piping
clamp and heater radiator unit sub-assy
3 Claws
I32496
55-26
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
30. REMOVE COOLER THERMISTOR NO.1
(a) Remove the clamp.
(b) Release the fitting claw, remove the 2 screws and heater
case.
Clamp
I32665
Claw
I32497
(c)
Release the fitting claw, remove the 5 screws and heater
case.
Claw
I32498
55-27
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
(d) Remove the cooler thermistor No. 1 from the cooler evap-
orator sub-assy No. 1.
I32666
31. REMOVE AIR CONDITIONING TUBE ASSY
(a) Remove the cooler evaporator assy from the heater case.
(b) Remove the packing.
I32500
(c)
Using a hexagon wrench 5.0 mm (0.20 in.), remove the
2 hexagon bolts and air conditioning tube assy.
(d) Remove the 2 O-rings from the air conditioning tube assy.
I32501
32. REMOVE COOLER EXPANSION VALVE
(a) Remove the cooler expansion valve from the cooler evap-
orator sub-assy No. 1.
(b) Remove the 2 O-rings from the cooler evaporator sub-
assy No. 1.
HINT:
Removing only instrument panel sub-assy upper, heater to reg-
ister duct No. 1 and heater case makes it possible and install
I32502
the cooler expansion valve.
33. REMOVE COOLER EVAPORATOR SUB-ASSY NO.1
34. REMOVE COOLER UNIT DRAIN HOSE NO.1
55-28
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
35. INSTALL COOLER EXPANSION VALVE
(a) Lubricate 2 new O-rings with compressor oil and install
them to the cooler expansion valve.
Compressor oil: ND-OIL 8 or equivalent
(b) Install the cooler expansion valve from cooler evaporator
sub-assy No. 1.
I32502
36. INSTALL AIR CONDITIONING TUBE ASSY
(a) Lubricate 2 new O-rings with compressor oil and install
them to the air conditioning tube assy.
Compressor oil: ND-OIL 8 or equivalent
(b) Using a hexagon wrench 5.0 mm (0.20 in.), install the air
conditioning tube assy with the 2 hexagon bolts.
Torque: 3.5 Nm (35 kgfcm, 30 in.lbf)
I32501
(c)
Install the packing.
HINT:
Securely attach so that the gap in the packing will not be mode.
(d) Install the cooler evaporator assy to the heater case.
I32500
37. INSTALL COOLER THERMISTOR NO.1
50 mm (2.0 in.)
(a) Install the cooler thermistor No. 1 at the shown position on
the illustration.
45 mm (1.77 in.)
I32503
55-29
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
(b) Install the heater case with the claw and 5 screws.
Claw
I32498
(c)
Install the heater case with the claw and 2 screws.
Claw
I32497
38. INSTALL AIR FILTER
(a) Install the air filter to the air conditioner unit assy.
I32504
55-30
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
39. INSTALL AIR CONDITIONER UNIT ASSY
(1)
(a) Install the air conditioner unit assy with the 4 nuts and bolt.
Torque: 9.8 Nm (100 kgfcm, 87 in.lbf)
(2)
(2)
NOTICE:
Tighten the nuts and bolt in following order shown in the il-
lustration to install the air conditioner unit assy.
(4)
(3)
I32489
(b) Connect the connector to the cooler thermistor No. 1.
I32488
(c)
Connect the connector to the damper servo sub-assy.
I32487
(d) Connect the connector to the blower w/ fan motor sub-
assy.
I32486
(e) Install the 2 fitting claws, connect the connector holder.
Lock Point
2 Claws
I32485
55-31
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
40. INSTALL ECM
(a) Install the ECM with the 2 bolts.
Torque: 3.0 Nm (30 kgfcm, 26 in.lbf)
NOTICE:
F
Do not apply excessive force to the connecter of the
ECM.
F
Do not give any impact to the ECM.
I32534
41. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER (See page
71-10)
42. INSTALL HEATER CONTROL & ACCESSORY ASSY (See page
55-13)
43. INSTALL DEFROSTER DAMPER CONTROL CABLE
FACE
DEF
SUB-ASSY
(a) Set the arm in FACE position.
(b) Install the inner cable end to the control lever with the arm
in FACE position.
(c)
Install the outer cable to the cable clamp while slightly
pressing it in the direction of the arrow.
NOTICE:
I32528
F
Be careful not to bend the cable wire.
F
If the cable wire bends, the heater control & accesso-
ry assy operationality becomes worse.
HINT:
Operating the mode control lever, check that it properly stops
at both ends of FACE and DEF and no recoil is identified.
44. INSTALL AIRMIX DAMPER CONTROL CABLE
SUB-ASSY
(a) Set the arm in MAX. COOL position.
(b) Install the inner cable end to the control lever with the arm
in MAX. COOL position.
(c)
Install the outer cable to the cable clamp while slightly
MAX.
pressing it in the direction of the arrow.
COOL
MAX. HOT
NOTICE:
I32529
F
Be careful not to bend the cable wire.
F
If the cable wire bends, the heater control & accesso-
ry assy operationality becomes worse.
HINT:
Operating the temperature control lever, check that it properly
stops at both ends of MAX. COOL and MAX. HOT and no recoil
is identified.
45.
REMOVE HEATER CONTROL & ACCESSORY ASSY (See page 55-13)
46.
INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (See page
71-10)
55-32
HEATER & AIR CONDITIONER
- AIR CONDITIONING UNIT ASSY
47. INSTALL HEATER OUTLET WATER HOSE
Marking
(a) Using pliers, grip the claws of clip and slide the clip and
connect the heater outlet water hose.
NOTICE:
90_
F
The clip is installing so that the projection of the clip
may go into the 90 _ to a direction position.
F
Marking of hose is installed upward by vehicle.
I32525
48. INSTALL HEATER INLET WATER HOSE
HINT:
Connect in the same way as the heater outlet water hose.
49. INSTALL COOLER REFRIGERANT SUCTION HOSE
NO.1
Connect
Wrong
Gap
(a) Lubricate a 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:
I06878
After connection, check the fitting for claw of the piping clamp.
50. INSTALL COOLER REFRIGERANT LIQUID PIPE A
(a) Lubricate a new O-ring with compressor oil and install them to the pipe.
Compressor oil: ND-OIL 8 or equivalent
(b) Install the cooler refrigerant liquid pipe A and piping clamp.
HINT:
After connection, check the fitting for claw of the piping clamp.
51. ADD COOLANT (See page 16-7)
52. CHECK ENGINE COOLANT LEAK (See page 16-1)
53. CHARGE REFRIGERANT (See page 55-11)
SST
07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,
07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140
Specified amount: 490
30 g (17.28
1.06 oz.)
54. WARM UP ENGINE
55. INSPECT LEAKAGE OF REFRIGERANT (See page 55-11)
55-33
HEATER & AIR CONDITIONER
- COOLER COMPRESSOR ASSY
COOLER COMPRESSOR ASSY
550IZ-01
COMPONENTS
Magnet Clutch Assy
Cooler Compressor Assy
_ Snap Ring
_ Snap Ring
18 (183, 13)
Magnet Clutch Washer
Nm (kgfcm, ftlbf)
: Specified torque
_ Non-Reusable part
I32420
55-34
HEATER & AIR CONDITIONER
- COOLER COMPRESSOR ASSY
550J0-01
REPLACEMENT
HINT:
COMPONENTS: See page 55-33
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page 55-11)
SST
07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070,
07117-88080)
2.
DISCONNECT COOLER REFRIGERANT SUCTION
HOSE NO.1
(a) Remove the bolt and disconnect the cooler refrigerant
suction hose No. 1 from the compressor and magnetic
clutch.
(b) Remove the O-ring from the cooler refrigerant suction
hose No. 1.
NOTICE:
I32458
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matter from entering.
3.
DISCONNECT DISCHARGE HOSE SUB-ASSY
(a) Remove the bolt and disconnect the discharge hose sub-
assy from the compressor and magnetic clutch.
(b) Remove the O-ring from the discharge hose sub-assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matter from entering.
I32459
4.
REMOVE ENGINE UNDER COVER RH
5.
REMOVE FAN AND GENERATOR V BELT (See page 14-4)
6.
REMOVE COMPRESSOR AND MAGNETIC CLUTCH
(a) Disconnect the connector.
(b) Remove the 3 bolts and compressor and magnetic clutch.
I32421
7.
REMOVE MAGNET CLUTCH ASSY
(a) Place the compressor and magnetic clutch in vise.

 

 

 

 

 

 

 

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