Removal and Installation
REMOVAL1. REMOVE FRONT WIPER AND OUTER FRONT COWL TOP PANEL
2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
HINT: At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrigerant.
Specified amount: 500 ± 50 g (17.64 ± 1.76 oz.)
3. DRAIN ENGINE COOLANT FROM RADIATOR
HINT: It is not necessary to drain out all coolant.
4. DISCONNECT LIQUID TUBE AND SUCTION HOSE
a. Using SST, remove the 2 piping clamps.
SST 09870-00015 (Suction tube)
09870-00025 (Liquid tube)
1. Insert SST to piping clamp.
HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label.
2. Push down SST and release the clamp lock.
NOTE: Be careful not to deform the tubes, when pushing SST.
3. Pull SST slightly and push the release lever, then remove the piping clamp with SST.
4. Remove the piping clamp from SST.
b. Disconnect the both tubes.
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.
HINT: At the time of reassembly, please refer to the following item.
Lubricate 4 new O-rings with compressor oil and install them to the valve.
5. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES
a. Using pliers, grip the claw of the hose clip and slide the hose clip along the hose.
b. Disconnect the heater hoses.
HINT: At the time of installation, please refer to the following item.
Push the water hose onto the heater radiator pipe as far as second ridge on the pipe and install the hose clip.
6. REMOVE INSTRUMENT PANEL AND REINFORCEMENT
7. REMOVE BLOWER UNIT
8. REMOVE A/C UNIT
a. Remove the 2 screws and defroster duct.
b. Remove the foot air duct.
c. Disconnect the connectors.
d. Remove the 2 nuts and A/C unit.
INSTALLATION
1. INSTALL A/C UNIT
HINT: Installation is in the reverse order of removal.
2. FILL ENGINE COOLANT AND BLEED AIR
a. Fill the radiator with engine coolant until it reaches the rim of the radiator filler.
If the engine coolant level of the radiator drops when grasping the radiator inlet hose outlet hose several times by hand, add more engine coolant.
b. Fill the radiator reservoir tank with engine coolant to the maximum level.
c. Install the radiator cap and start the engine. After repeatedly idling and racing the engine several times for approx. 2 minutes, stop the engine.
d. Remove the radiator cap and fill the radiator with engine coolant until it reaches the rim of the radiator filler.
If the engine coolant level of the radiator drops when grasping the radiator inlet hose and outlet hose several times by hand, add more coolant.
e. Install the radiator cap. Activate inspection mode. Warm it up until the radiator fan starts to turn with the engine speed at less than 2,500 rpm.
NOTE: Stop the engine immediately after the radiator fan starts to turn.
f. Stop the engine and cool it down.
NOTE: Cool down the engine until its temperature becomes below 50 °C (122 °F).
g. Remove the radiator cap and check the engine coolant level of the radiator. If it has dropped, repeat steps (d) to (g).
h. Bleed air from water pump.
Set the vehicle in the following conditions:
- Ignition switch ON
- Blower speed control dial to LO
- Temperature control dial to MAX. HOT
i. Operate the water pump in the following conditions:
- The engine stopped
- The blower switch ON
- Temperature control dial at MAX. HOT
HINT: Operate the water pump until a sound of the air-containing engine coolant can not be heard from the heater core.
j. When the engine coolant remains full, fill the radiator reservoir tank with engine coolant to the maximum level.