1712-1U-01G(07-11).

fm 1 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
07–11 BASIC SYSTEM
BASIC SYSTEM LOCATION INDEX . . . 07–11–2 HEATER CORE INSPECTION . . . . . . . . . 07–11–10
BLOWER UNIT AIRFLOW MODE MAIN LINK
REMOVAL/INSTALLATION . . . . . . . . . 07–11–3 REMOVAL/INSTALLATION . . . . . . . . . . 07–11–10
BLOWER UNIT Airflow Mode Main Link
DISASSEMBLY/ASSEMBLY . . . . . . . . 07–11–3 Installation Note . . . . . . . . . . . . . . . . . 07–11–10
COOLING UNIT REAR DUCT
REMOVAL/INSTALLATION . . . . . . . . . 07–11–3 REMOVAL/INSTALLATION . . . . . . . . . . 07–11–11
Cooling Unit Installation Note. . . . . . . . 07–11–4 REAR HEAT DUCT
COOLING UNIT REMOVAL/INSTALLATION . . . . . . . . . . 07–11–11
DISASSEMBLY/ASSEMBLY . . . . . . . . 07–11–4 A/C COMPRESSOR
Expansion Valve Assembly Note . . . . . 07–11–5 REMOVAL/INSTALLATION . . . . . . . . . . 07–11–11
Evaporator Assembly Note . . . . . . . . . 07–11–6 A/C Compressor Installation Note. . . . . 07–11–12
Adhesive Sponge Rubber CONDENSER
Assembly Note. . . . . . . . . . . . . . . . . . 07–11–6 REMOVAL/INSTALLATION . . . . . . . . . . 07–11–12
Insulator Assembly Note . . . . . . . . . . . 07–11–6 Condenser Installation Note . . . . . . . . . 07–11–13
A/C Amplifier Assembly Note . . . . . . . . 07–11–6 CONDENSER INSPECTION . . . . . . . . . . 07–11–13
Sensor Clamp Assembly Note . . . . . . . 07–11–7 RECEIVER/DRIER
Polyethylene Foam Assembly Note . . . 07–11–7 REMOVAL/INSTALLATION . . . . . . . . . . 07–11–13
EVAPORATOR INSPECTION. . . . . . . . . 07–11–7 Receiver/drier Installation Note . . . . . . . 07–11–14
HEATER UNIT REFRIGERANT
REMOVAL/INSTALLATION . . . . . . . . . 07–11–7 LINES REMOVAL/INSTALLATION . . . . 07–11–14 07–11
HEATER UNIT Refrigerant Lines Removal Note . . . . . . 07–11–15
DISASSEMBLY/ASSEMBLY . . . . . . . . 07–11–9 Refrigerant Lines Installation Note . . . . 07–11–16

End of Toc

07–11–1
1712-1U-01G(07-11).fm 2 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
BASIC SYSTEM LOCATION INDEX
A3U071101040W01

Z3U0711W001

1 Blower unit 5 Rear heat duct

(See 07–11–3 BLOWER UNIT REMOVAL/ (See 07–11–11 REAR HEAT DUCT REMOVAL/
INSTALLATION) INSTALLATION)
(See 07–11–3 BLOWER UNIT DISASSEMBLY/ 6 A/C compressor
ASSEMBLY) (See 07–11–11 A/C COMPRESSOR REMOVAL/
2 Heater unit INSTALLATION)
(See 07–11–7 HEATER UNIT REMOVAL/ 7 Condenser
INSTALLATION) (See 07–11–12 CONDENSER REMOVAL/
(See 07–11–9 HEATER UNIT DISASSEMBLY/ INSTALLATION)
ASSEMBLY) (See 07–11–13 CONDENSER INSPECTION)
3 Cooling unit 8 Receiver/drier
(See 07–11–3 COOLING UNIT REMOVAL/ (See 07–11–13 RECEIVER/DRIER REMOVAL/
INSTALLATION) INSTALLATION)
(See 07–11–4 COOLING UNIT DISASSEMBLY/
ASSEMBLY) 9 Refrigerant lines
(See 07–11–14 REFRIGERANT LINES REMOVAL/
4 Rear duct INSTALLATION)
(See 07–11–11 REAR DUCT REMOVAL/
INSTALLATION)

End Of Sie

07–11–2
1712-1U-01G(07-11).fm 3 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
A3U071161140W01
1. Disconnect the negative battery cable.
2. Remove the dashboard. (See 09–17–1 DASHBOARD REMOVAL/INSTALLATION.)
3. Remove the cooling unit. (See 07–11–3 COOLING UNIT REMOVAL/INSTALLATION.)
4. Remove the blower unit.
5. Install in the reverse order of removal.
End Of Sie

07–11

Z3U0711W002

BLOWER UNIT DISASSEMBLY/ASSEMBLY

A3U071161140W02
1. Disassemble in the order indicated in the table.
1 Blower motor
2 Blower harness
3 Air intake actuator
4 Air intake crank
5 Air intake door
6 Polyurethane protector
7 Blower case (1)
8 Blower case (2)

2. Assemble in the reverse order of disassembly.

End Of Sie

Z3U0711W003

COOLING UNIT REMOVAL/INSTALLATION

A3U071161520W01
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07–10–3 REFRIGERANT CHARGING.)
3. Remove the passenger-side lower panel.
4. Remove the glove compartment and glove compartment cover.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.

07–11–3
1712-1U-01G(07-11).fm 4 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
5. Disconnect cooler pipe No.3 and cooler hose
(LO). (See 07–11–15 Refrigerant Lines Removal
Note.) (See 07–11–16 Refrigerant Lines
Installation Note.)

Z3U0711W004

6. Remove in the order indicated in the table. Do not

allow compressor oil to spill.
1 Connector
2 Cooling unit
(See 07–11–4 Cooling Unit Installation Note)

7. Install in the reverse order of removal.

8. Perform the refrigerant system performance test.
(See 07–10–2 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

Z3U0711W005

Cooling Unit Installation Note

1. When installing a new cooling unit (evaporator), add a supplemental amount of ATMOS GU10 compressor oil
into the refrigeration cycle.

Supplemental amount (approximate quantity)

30 ml {30 cc, 1.0 fl oz}

End Of Sie
COOLING UNIT DISASSEMBLY/ASSEMBLY
A3U071161520W02
1. Disassemble in the order indicated in the table.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.

07–11–4
1712-1U-01G(07-11).fm 5 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
1 Resistor
2 Polyurethane foam
3 Polyurethane protector (1)
4 Polyurethane protector (2)
5 Cooler case (1)
6 Cooler case (2)
7 Polyethylene foam
(See 07–11–7 Polyethylene Foam Assembly Note)
8 Sensor clamp
(See 07–11–7 Sensor Clamp Assembly Note)
9 A/C amplifier
(See 07–11–6 A/C Amplifier Assembly Note)
10 Insulator
(See 07–11–6 Insulator Assembly Note)
11 Adhesive sponge rubber
(See 07–11–6 Adhesive Sponge Rubber Assembly
Note)
12 Sponge rubber
13 Polyurethane protector (3)
14 Polyethylene protector
15 Polyurethane protector (4)
Z3U0711W006
07–11
16 Evaporator
(See 07–11–6 Evaporator Assembly Note)
17 Expansion valve
(See 07–11–5 Expansion Valve Assembly Note)

2. Assemble in the reverse order of disassembly.

Expansion Valve Assembly Note

1. Apply compressor oil to the O-rings and connect the joint.
2. Tighten the nut of the joint by hand.
3. Tighten the joint with the specified torque with a spanner and torque wrench.
4. Assemble the heat-sensing tube as shown in the figure.
5. Route the capillary tube as shown in the figure.

Z3U0711W007

6. Verify that the capillary tube is not in the shaded

zone

Z3U0711W008

07–11–5
1712-1U-01G(07-11).fm 6 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
Evaporator Assembly Note
1. Verify that the dent caused by contact with the
polyuretane protector and cooler case (1) in the
shaded zone is 3 mm {0.12 in} or less.

A3U0711W002

Adhesive Sponge Rubber Assembly Note

1. Attach the adhesive sponge rubber so that the
heat sensing tube is hidden.

Z3U0711W010

Insulator Assembly Note

1. Make the two insulators cross.
2. Attach the insulator so that the shaded zone of
expansion valve is hidden.

Z3U0711W011

A/C Amplifier Assembly Note

1. Assemble the evaporator temperature sensor as
shown in the figure.

Z3U0711W012

07–11–6
1712-1U-01G(07-11).fm 7 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
Sensor Clamp Assembly Note
1. Assemble the sensor clamp as shown in the
figure.

Z3U0711W013

Polyethylene Foam Assembly Note

1. Apply the adhesive to a range of 50 mm {1.97 in}
from the edge of polyethylene foam, and around
the drain outlet. Apply the polyethylene foam to
the cooler case (2).
End Of Sie

07–11

Z3U0711W014

EVAPORATOR INSPECTION
A3U071161810W01
1. Remove the cooling unit. (See 07–11–3 COOLING UNIT REMOVAL/INSTALLATION.)
2. Remove the evaporator from the cooling unit.
3. Inspect for cracks, damage, and oil leakage.
• If any problems are found, replace the evaporator.
4. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
End Of Sie
HEATER UNIT REMOVAL/INSTALLATION
A3U071161130W01
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01–12–3 ENGINE COOLANT REPLACEMENT.)
3. Remove the dashboard. (See 09–17–1 DASHBOARD REMOVAL/INSTALLATION.)
4. Remove the cooling unit. (See 07–11–3 COOLING UNIT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.

X3U711WAB

07–11–7
1712-1U-01G(07-11).fm 8 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
1 Heater hose
2 Heater unit
3 Rear duct
4 Heat duct

6. Install in the reverse order of removal.

End Of Sie

X3U711WAC

07–11–8
1712-1U-01G(07-11).fm 9 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
HEATER UNIT DISASSEMBLY/ASSEMBLY
A3U071161130W02
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly. .

07–11

A3U0711W003

1 Air mix link 10 Airflow mode sub link (1)

2 Air mix rod (2) 11 Airflow mode sub link (2)
3 Air mix crank (1) 12 Airflow mode sub link (3)
4 Air mix rod (1) 13 Airflow mode crank
5 Air mix crank (2) 14 Heater case (1)
6 Wire clamp 15 Heater case (2)
7 Wire clamp 16 Heater case (3)
8 Bracket 17 Heater case (4)
9 Airflow mode main link 18 Heater core
(See 07–11–10 Airflow Mode Main Link Installation
Note)

07–11–9
1712-1U-01G(07-11).fm 10 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
End Of Sie
HEATER CORE INSPECTION
A3U071161910W01
1. Remove the heater unit. (See 07–11–7 HEATER UNIT REMOVAL/INSTALLATION.)
2. Remove the heater core from the heater unit.
3. Inspect for cracks, damage, and coolant leakage.
• If any problems are found, replace the heater core.
4. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
5. Verify that the heater core inlet and outlet are not distorted or damaged. Repair with pliers if necessary.
End Of Sie
AIRFLOW MODE MAIN LINK REMOVAL/INSTALLATION
A3U071161030W01
1. Disconnect the airflow mode wire from the airflow mode main link.
2. Remove in the airflow mode main link. (See 07–
11–10 Airflow Mode Main Link Installation Note)
3. Install in the reverse order of removal.
4. Adjust the airflow mode wire. (See 07–40–11
CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)

Z3U0711W024

Airflow Mode Main Link Installation Note

Caution
• If any grease other than the specified grease is applied to the links, abnormal noise will occur or
the links will not properly operate. Therefore, do not apply any grease to the links.

1. Push and hold each airflow mode sub link in the

direction shown by the arrow.

X3U711WAF

2. Set the airflow mode main link to the heater unit

as shown in the figure.
3. Press the airflow mode main link lightly and rotate
it in the direction shown by the arrow, then set the
projections of each airflow mode sub link into the
grooves of the airflow mode main link.
4. Rotate airflow mode main link and verify that each
mode is accessed properly.
End Of Sie

X3U711WAG

07–11–10
1712-1U-01G(07-11).fm 11 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
REAR DUCT REMOVAL/INSTALLATION
A3U071161271W01
1. Remove the side wall.
2. Remove in the rear duct.
3. Install in the reverse order of removal.
End Of Sie

Z3U0711W025

REAR HEAT DUCT REMOVAL/INSTALLATION

A3U071161273W01
1. Turn the floor covering over. (See 09–17–17 FLOOR COVERING REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
1 Rear heat duct (RH)
2 Rear heat duct (LH)

3. Install in the reverse order of removal.

07–11
End Of Sie

X3U711WAJ

A/C COMPRESSOR REMOVAL/INSTALLATION

A3U071161450W01
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07–10–3 REFRIGERANT RECOVERY.) (See 07–10–3
REFRIGERANT CHARGING.)
3. Remove the splash shield (RH) and fresh-air duct.
4. Loosen the mounting bolts, nuts, and the adjusting lock bolt of the power steering oil pump.
5. Loosen the drive belt (P/S + A/C) and remove it. (See 01–10B–4 DRIVE BELT ADJUSTMENT [FS].)

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.

07–11–11
1712-1U-01G(07-11).fm 12 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
6. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
1 Cooler hose (HI)
(See 07–11–16 Refrigerant Lines Installation Note)
2 Cooler hose (LO)
(See 07–11–16 Refrigerant Lines Installation Note)
3 Connector
4 A/C compressor
(See 07–11–12 A/C Compressor Installation Note)

7. Install in the reverse order of removal.

8. Adjust the drive belt (P/S + A/C). (See 01–10B–4
DRIVE BELT ADJUSTMENT [FS].)
9. Perform the refrigerant system performance test.
(See 07–10–2 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

Y3U711WA1

A/C Compressor Installation Note

1. Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C
compressor.

Compressor oil to be removed (approximate quantity)

150 ml {150 cc, 5.07 fl oz} - [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz}]

End Of Sie
CONDENSER REMOVAL/INSTALLATION
A3U071161480W01
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07–10–3 REFRIGERANT CHARGING.)
3. Pull up the coolant reservoir.
4. Remove the fresh-air duct, radiator bracket, air cleaner, resonance chamber, and mass airflow sensor
connector.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.

Note
• Two kinds of condensers are used:
— TYPE A (condenser without pipe)
— TYPE B (condenser with pipe)

07–11–12
1712-1U-01G(07-11).fm 13 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
1 Cooler hose (HI)
(See 07–11–16 Refrigerant Lines Installation Note)
2 Cooler pipe No.1 (type A) or outlet pipe of
condenser (type B)
(See 07–11–16 Refrigerant Lines Installation Note)
3 Condenser
(See 07–11–13 Condenser Installation Note)

6. Install in the reverse order of removal.

7. Perform the refrigerant system performance test.
(See 07–10–2 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

Z3U0711W016
07–11

Condenser Installation Note

1. When installing a new condenser, add a supplemental amount of ATMOS GU10 compressor oil into the
refrigeration cycle.

Supplemental amount (approximate quantity)

30 ml {30 cc, 1.0 fl oz}

End Of Sie
CONDENSER INSPECTION
A3U071161480W02
1. Inspect for cracks, damage, and oil leakage.
• If any are found, replace the condenser.
2. Inspect for fins clogged by dust.
• If any are clogged, remove the dust from the fins.
3. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
End Of Sie
RECEIVER/DRIER REMOVAL/INSTALLATION
A3U071161501W01
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07–10–3 REFRIGERANT RECOVERY.) (See 07–10–3
REFRIGERANT CHARGING.)
3. Pull up the coolant reservoir.
4. Remove the fresh-air duct, air cleaner, and resonance chamber.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.

07–11–13
1712-1U-01G(07-11).fm 14 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
1 Cooler pipe No.2
(See 07–11–16 Refrigerant Lines Installation Note)
2 Cooler pipe No.1 (type A) or outlet pipe of
condenser (type B)
(See 07–11–16 Refrigerant Lines Installation Note)
3 Connector
4 Receiver/drier
(See 07–11–14 Receiver/drier Installation Note)

6. Install in the reverse order of removal.

7. Perform the refrigerant system performance test.
(See 07–10–2 REFRIGERANT SYSTEM
PERFORMANCE TEST.)

A3U0711W001

Receiver/drier Installation Note

1. When installing a new receiver/drier, add a supplemental amount of ATMOS GU10 compressor oil into the
refrigeration cycle.

Supplemental amount (approximate quantity)

10 ml {10 cc, 0.3 fl oz}

End Of Sie
REFRIGERANT LINES REMOVAL/INSTALLATION
A3U071161460W01
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07–10–3 REFRIGERANT RECOVERY.) (See 07–10–3
REFRIGERANT CHARGING.)
3. Pull up the coolant reservoir.
4. Remove the fresh-air duct, radiator bracket, air cleaner, and resonance chamber.

Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.
6. Install in the reverse order of removal.

07–11–14
1712-1U-01G(07-11).fm 15 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
7. Perform the refrigerant system performance test. (See 07–10–2 REFRIGERANT SYSTEM PERFORMANCE
TEST.) .

07–11

Z3U0711W018

1 Cooler pipe No.1 (type A only) 4 Cooler hose (HI)

(See 07–11–16 Refrigerant Lines Installation Note) (See 07–11–16 Refrigerant Lines Installation Note)
2 Cooler pipe No.2 5 Cooler hose (LO)
(See 07–11–15 Refrigerant Lines Removal Note) (See 07–11–15 Refrigerant Lines Removal Note)
(See 07–11–16 Refrigerant Lines Installation Note) (See 07–11–16 Refrigerant Lines Installation Note)
3 Cooler pipe No.3
(See 07–11–15 Refrigerant Lines Removal Note)
(See 07–11–16 Refrigerant Lines Installation Note)

Refrigerant Lines Removal Note

Nut joint type
1. Loosen the nut using 2 spanners, then remove the cooler pipe or hose.

Spring-lock coupling type

1. Set the SST.

Z3U0711W019

07–11–15
1712-1U-01G(07-11).fm 16 ページ ２００１年６月２９日 金曜日 午前１０時２０分

BASIC SYSTEM
2. While looking through the inspection hole of the
SST, insert the protruding part of the SST until it
makes contact with the gauge section.
3. Use the SST to disconnect the cooler hose (LO)
from cooling unit by pulling the cooler hose (LO)
side.

Note
• The cooler hose (LO) can be disconnected
easily from cooling unit by pulling from the
cooler hose (LO) while maintaining the
pressure of the protruding part of the SST.
Z3U0711W020

Z3U0711W021

Refrigerant Lines Installation Note

1. When installing a new cooler pipe or hose, add a supplemental amount of ATMOS GU10 compressor oil into
the refrigeration cycle.
Supplemental amount (approximate quantity)
5 ml {5 cc, 0.2 fl oz}
2. Apply compressor oil to the O-rings and connect the joints.
3. Tighten the joints.
Nut or block joint type
1. Tighten the nut or bolt of the joint by hand.
2. Tighten the joint to the specified torque wrench.
Spring-lock coupling type
1. Connect the cooler hose (LO) by twisting it onto
cooling unit until the garter spring at the cooler
hose (LO) is over the flared end of cooling unit.

Z3U0711W022

Note
• When the cooler hose (LO) is replaced, the
indicator ring comes out after connecting to
indicate that it is locked.
End Of Sie

Z3U0711W023

07–11–16