Air Conditioning Unit: Reassembly

INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator.
  Compressor oil:
  
  ND-OIL 11 or equivalent
  
  Fig 1: Identifying Damper Servo Motor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 O-rings on the cooler evaporator.
  
  Fig 2: Identifying O-Rings On Cooler Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the air duct with the 3 claws and 5 screws.
  
  Fig 3: Identifying Air Duct With Claws And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit with the clamp and screw.
  
  Fig 4: Identifying Clamp With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVO MOTOR LH
1. Install the air mix control servo motor with the 3 screws.
  
  Fig 5: Locating Air Mix Control Servomotor With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the drive gear to the air outlet control servo motor. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servo motor.
  NOTE:
  - The number of gear teeth from the standard position varies according to the stop position of the air outlet control servo motor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servo motor may not operate normally. If so, remove the drive gear, adjust the driven gear, and reinstall the drive gear.
    
    Fig 6: Identifying Drive Gear And Air Outlet Control Servo Motor Engaged Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR LH
1. Attach the claw and install the air mix control servo motor with the 3 screws.
2. Install the drive gear to the air mix control servo motor.
3. Temporarily install the mode damper servo so that the levers fit into each groove.
  
  Fig 7: Identifying Air Mix Control Servo Motor LH With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Slightly lift the mode damper servo. Check that the drive gear and driven gear are engaged at a point with the same number of gear teeth from the standard position from the view indicated by arrow (A).
  NOTE: If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the mode damper servo may not operate normally. If so, lift the mode damper to adjust the driven gear and reinstall the drive gear.
5. Install the mode damper with the 4 screws.
  
  Fig 8: Identifying Drive Gear And Air Outlet Control Servo Motor Engaged Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the air duct with the 2 screws.
  
  Fig 9: Identifying Air Duct With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING HARNESS ASSEMBLY
1. Attach the 4 clamps to install the wire harness.
2. Install the A/C harness as shown in the illustration.
  
  Fig 10: Identifying Clamps On Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 2 connectors and attach the clamp.
  
  Fig 11: Locating Connectors And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR RH
1. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Temporarily install the air mix control servo motor.
  NOTE:
  - The number of gear teeth from the standard position varies according to the stop position of the air mix control servo motor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air mix control servo motor may not operate normally. If so, remove the drive gear, adjust the driven gear, and reinstall the drive gear.
    
    Fig 12: Identifying Drive Gear And Driven Gear Engaged Position
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the air mix control servo motor with the 3 screws.
3. Install the heater piping cover with the 2 screws.
  
  Fig 13: Locating Heater Piping Cover Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 4 clamps and connect the connector to connect the wire harness.
  
  Fig 14: Identifying Clamps And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVO MOTOR RH
1. Install the servo motor with the 3 screws.
2. Connect the connector.
  
  Fig 15: Locating Air Outlet Control Servo Motor And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. Install the cooler expansion valve to the cooler evaporator.
  
  Fig 16: Identifying Cooler Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING TUBE ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the A/C tube.
  Compressor oil:
  
  ND-OIL 11 or equivalent
2. Install the 2 O-rings on the A/C tube.
3. Using a 4 mm hexagon wrench, install the A/C tube with the 2 hexagon bolts.
  Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf)
  
  Fig 17: Identifying A/C Tube With Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new packing.
  
  Fig 18: Identifying Packing On A/C Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002