Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NO. 1 COOLER UNIT DRAIN HOSE
INSTALL COOLER THERMISTOR SENSOR
1. Engage the 2 clamps and install the cooler thermistor sensor.
  
  Fig 1: Installing Cooler Thermistor Sensor & Engaging Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXPANSION VALVE
1. Apply sufficient compressor oil to 2 new seal washers and the fitting surface of the expansion valve.
  Compressor oil: RL-897 or equivalent
2. Install the 2 seal washers onto the expansion valve.
3. Using "Torx" socket wrench T25, install the expansion valve with the 2 bolts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 2: Installing New Seal Washers Onto Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE TO CONNECTOR TUBE
1. Apply sufficient compressor oil to 2 new seal washers and fitting surface of the valve to connector tube.
  Compressor oil: RL-897 or equivalent
2. Install the 2 seal washers onto the valve to connector tube.
3. Using "Torx" socket wrench E10, install the air conditioning tube assembly with the bolt.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
  
  Fig 3: Installing New Seal Washers Onto Valve To Connector Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EVAPORATOR CORE
1. Attach the evaporator side seal to both sides of the evaporator.
  
  Fig 4: Attaching Evaporator Side Seal To Both Sides Of Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Attach the evaporator top seal to the upper side and the evaporator bottom seal to the lower side of the evaporator.
  
  Fig 5: Attaching Evaporator Top Seal To Upper Side & Evaporator Bottom Seal To Lower Side Of Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align and apply the expansion valve seal to the periphery of the expansion valve protrusions on the back side of the expansion valve.
  
  Fig 6: Aligning & Applying Expansion Valve Seal To Periphery Of Expansion Valve Protrusions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align and attach the 2 different seals to the evaporator inlet and outlet pipes.
  
  Fig 7: Aligning & Attaching Different Seals To Evaporator Inlet & Outlet Pipes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the evaporator core.
  
  Fig 8: Installing Evaporator Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the mode case with the clip and 11 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 9: Installing Mode Case With Clip & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the heater pivot with the bolt.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 10: Installing Heater Pivot With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the mode cam.
  
  Fig 11: Installing Mode Cam
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install the mode mounting plate with the 3 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 12: Installing Mode Mounting Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER MOTOR
1. Install the blower motor with the 3 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 13: Installing Blower Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER RESISTOR
1. Install the blower resistor with the 2 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 14: Installing Blower Resistor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR ASSEMBLY
1. Apply the heater core short seal to both sides of the heater core.
  
  Fig 15: Applying Heater Core Short Seal To Both Sides Of Heater Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply the heater core long seal to the upper and lower sides of the heater core.
  
  Fig 16: Applying Heater Core Long Seal To Upper & Lower Sides Of Heater Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply the heater core header seal to the right side of the heater core.
  
  Fig 17: Applying Heater Core Header Seal To Right Side Of Heater Core
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using "Torx" socket wrench T30, install the heater radiator assembly with the bolt and clamp.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 18: Installing Heater Radiator Assembly With Bolt & Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the heater cover case with the 8 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 19: Installing Heater Cover Case With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the temperature cam.
  
  Fig 20: Installing Temperature Cam
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the temperature mounting plate with the 3 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 21: Installing Temperature Mounting Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR INLET CONTROL SERVO MOTOR
1. Install the air inlet control servo motor with the 2 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 22: Installing Air Inlet Control Servo Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR
1. Install the air mix control servo motor with the 2 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 23: Installing Air Mix Control Servo Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MODE CONTROL SERVO MOTOR
1. Install the mode control servo motor with the 3 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 24: Installing Mode Control Servo Motor With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR FILTER
1. Install the air filter.
  NOTE: Check the installation direction as shown in Fig 25 and install the air filter.
2. Engage the 2 tabs and close the filter door.
  
  Fig 25: Installing Air Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 AIR DUCT
1. Engage the 3 claws and install the air duct.
2. Install the bolt.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 26: Installing No. 1 Air Duct With Bolt & Engaging Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER TO REGISTER CENTER DUCT
1. Install the heater to register duct center with the 2 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 27: Installing Heater To Register Duct Center With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DEFROSTER NOZZLE ASSEMBLY LOWER
1. Install the defroster nozzle assembly lower with the 4 bolts.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 28: Installing Defroster Nozzle Assembly Lower With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002