Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL COOLER EXPANSION VALVE
1. Sufficiently apply compressor oil to 4 new O-rings and the fitting surface of the hose joint.
  Compressor oil: ND-OIL 8 or equivalent
2. Install the 2 O-rings to the cooler evaporator.
3. Install the 2 O-rings to the tube and accessory.
4. Install the cooler expansion valve and tube and accessory to the evaporator.
5. Using a 4 mm hexagon wrench, install the 2 bolts.
  Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf)
  
  Fig 1: Identifying Cooler Expansion Valve Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL EVAPORATOR TEMPERATURE SENSOR

NOTE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted.

Insert the sensor to a location that is 1 fin to the right or left of its previous location.

AREA DIMENSION TABLE

Area	Standard Dimension
a	48 mm (1.89 in.)
b	9 mm (0.354 in.)
c	34.3 mm (1.35 in.)
d	47.7 mm (1.88 in.)
e	50 mm (1.97 in.)

Fig 2: Identifying Evaporator Temperature Sensor Position

INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Install the evaporator to the blower case (front side).
  
  Fig 3: Identifying Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the blower case (back side).
3. Install the 6 screws and attach the 4 claws.
  
  Fig 4: Locating Blower Case Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the packing as shown below.
  
  Fig 5: Identifying Packing Area
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit.
2. Attach the 3 claws to install the heater clamp.
  
  Fig 6: Locating Heater Radiator Unit With Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the plate with the 3 screws.
  
  Fig 7: Identifying Heater Radiator Unit Plate And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)
1. Install the damper servo with the 3 screws, as shown below.
2. Connect the connector.
  
  Fig 8: Locating Cooling Unit Damper Servo Sub-Assembly With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY
1. Install the damper servo with the 3 screws.
2. Connect the connector.
  
  Fig 9: Identifying Damper Servo Screws And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER CASE SUB-ASSEMBLY
1. Attach the 3 claws to install the case.
2. Install the 3 screws.
  
  Fig 10: Identifying Blower Case Sub-Assembly Claws With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DAMPER SERVO SUB-ASSEMBLY
1. Install the damper servo with the 3 screws.
2. Connect the connector.
  
  Fig 11: Identifying Damper Servo Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DAMPER SERVO SUB-ASSEMBLY
1. Install the servo motor.
  1. Set the plate so that the cutout part engages with the tooth of the gear, and attach the claw to install the main plate.
  2. Install the 2 screws.
    
    Fig 12: Locating Damper Servo Sub-Assembly Screws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the servo motor.
  1. Insert the pin into the plate groove.
  2. Attach the claw to install the main plate.
  3. Install the 2 screws.
    
    Fig 13: Locating Main Plate Claw And Screw
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the damper servo.
  
  Fig 14: Identifying Rotator Lever Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 4 screws and connect the 2 connectors.
  
  Fig 15: Locating Damper Servo Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR DUCT
1. Install the duct with the 2 screws.
  
  Fig 16: Locating Air Duct Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY
1. Install the motor with the 3 screws.
  
  Fig 17: Locating Blower With Fan Motor Sub-Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
1. Install the amplifier with the 2 screws.
  
  Fig 18: Identifying Air Conditioning Amplifier Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
1. install the duct with the screw.
  
  Fig 19: Identifying No. 2 Air Duct Sub-Assembly Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLEAN AIR FILTER
1. Install the filter as shown below.
  
  Fig 20: Identifying Clean Air Filter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR FILTER COVER PLATE
1. Attach the 2 clips to install the plate.
  
  Fig 21: Identifying Air Filter Cover Plate Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
1. Attach the 4 claws to install the duct.
  
  Fig 22: Identifying No. 3 Air Duct Sub-Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
1. Attach the 4 claws to install the nozzle.
  
  Fig 23: Identifying Lower Defroster Nozzle Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002