[CBR_GUY_IA]

HEATING & AIR CONDITIONING
AC002-07

Title:
HVAC BLOWER MOTOR ICE BUILD-UP

Models:
'03 - '07 4Runner

May 18, 2007

The information contained in this TSB supersedes TSB No. AC003-03. TSB No. ACOO3-03 is now obsolete and should be discarded.

Introduction

Some 2003 - 2007 model year 4Runner vehicles may experience a condition where the blower volume will gradually decrease due to ice build-up in the blower motor housing. This TSB provides information for a field-fix repair to improve this condition. Follow the repair procedures described below.

Applicable Vehicles

^ 2003 - 2007 model year 4Runner vehicles.

^ ONLY perform Repair Procedure No.1 if the VIN falls BEFORE the Production Change Effective VIN listed in the following Production Change Information table.

^ Perform Repair Procedure No.2 on ALL vehicles.








Production Change Information







Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Parts Information

Repair Procedure No. 1

NOTE :ONLY perform Repair Procedure No.1 if the VIN falls BEFORE the Production Change Effective VIN listed in the Production Change Information table.

1. Select air source.

A. Turn the ignition switch to the ON position.

B. Turn the air select switch to the recirculating position.

C. Turn the ignition switch off and disconnect the negative battery terminal.


WARNING :Failure to complete step "C" above may result in internal damage to the transfer case shifting mechanism.







2. Remove instrument panel under cover sub-assembly No. 2.

A. Remove the screw.

B. Disengage the 3 clips and remove the instrument panel under cover sub-assembly No. 2.









3. Remove the glove compartment door sub-assembly.

A. Remove the screw and disconnect the glove compartment door stopper.

B. Press in on the upper part of the sides of the glove compartment door to release the stoppers.

C. Pull the glove compartment door upward to remove it.









4. Remove instrument panel finish panel lower No. 2.

A. Remove the 4 screws.

B. Disengage the 2 claws and remove the instrument panel finish panel lower No. 2.









5. Remove the air filter cover plate with air filter element.








6. Install the blower case packing.

A. Peel off the adhesive backing from the blower case packing.









B. Install the blower case packing into the pocket on the left side of the blower case as shown in the illustration.

NOTE :Put the blower case packing on the lower surface of the case.

7. Remove the blower w/fan motor sub-assembly.








A. Disconnect the connector from the blower motor.








B. Remove the 3 bolts and blower motor.

8. Apply sealant.








A. Blow air into the cooling air intake of the blower motor to remove any remaining water.








B. Using a cloth, wipe any water, dirt or dust from inside the blower case.








C. Apply sealant to the contact surface of the blower case, as shown in the illustration.

D. Rub the sealant onto the contact surface with your finger while wearing vinyl gloves (or equivalent).

NOTE :^ Apply the sealant to an area twice the width of the rib.

^ Be careful NOT to clog the water drain hole with sealant.

^ Be sure to ventilate by opening the vehicle's doors when applying sealant.








E. Wipe off the excess sealant with a cloth before it dries.

F. Make sure that the clearance between the contact surface of the case, especially at the rib, is filled with sealant.

G. Wait for approximately 1 hour to let the sealant dry.








9. Install the NEW blower w/fan motor sub-assembly.

A. Install a NEW blower motor with the 3 bolts.

B. Connect the connector to the blower motor.









10. Install the air filter cover plate with air filter element.

11. Install the glove compartment door sub-assembly.

12. Install instrument panel under cover sub-assembly No. 2.

13. Reconnect the negative (-) terminal of the battery.

14. Re-initialize auto power windows and sliding moon roof.

^ 2003, 2004, or 2005 model year 4Runner, refer to TSB No. PD008-05, "Power System Initialization During PDS".

^ 2006 model year 4Runner, refer to TSB No. PD014-06, "Power System Initialization During PDS".

^ 2007 model year 4Runner, refer to TSB No. PD01 0-07, "Power System Initialization During PDS".



Repair Procedure No. 2

Perform Repair Procedure No. 2 on ALL vehicles.

Remove and replace the cowl top ventilator louver sub-assembly. Refer to the Technical Information System (TIS):

^ 2003, 2004, or 2005 model year 4Runner Repair Manual, Vehicle Exterior - Wiper/Washer - "Windshield Wiper Motor Assy: Replacement"

^ 2006 or 2007 model year 4Runner Repair Manual:

^ Vehicle Exterior - Wiper/Washer - "Wiper And Washer: Front Wiper Motor: Removal"

^ Vehicle Exterior - Wiper/Washer - "Wiper And Washer: Front Wiper Motor: Installation"