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Air Conditioning Unit: Reassembly: Reassembly

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  1. INSTALL AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY 
    1. Check that the slots, links and gears of the air outlet control servo motor sub-assembly are positioned in the correct orientation as shown in the illustration.
      Fig 1: Checking Slots, Links And Gears Of Air Outlet Control Servo Motor Sub-Assembly
      GTY298523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Face the contact surfaces of the air outlet control servo motor sub-assembly and air conditioning radiator assembly for the air outlet control servo motor sub-assembly upward.
    3. Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.
      Fig 2: Rotating Link Of Air Conditioning Radiator Assembly (To The Left)
      GTY298998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Rotate the link of the air conditioning radiator assembly to the bottom as shown in the illustration and confirm that the mode switching duct hole is fully closed.
      Fig 3: Rotating Link Of Air Conditioning Radiator Assembly (To The Bottom)
      GTY295333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Mode Switching Duct Hole - -
    5. Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.
      Fig 4: Rotating Lever Of Air Conditioning Radiator Assembly (To The Top)
      GTY301423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.
      Fig 5: Rotating Link Of Air Conditioning Radiator Assembly (To In-Line Position)
      GTY301884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a In-line Position - -
    7. Wrap the upper and lower links with vinyl tape to hold them in the in-line position.
      Fig 6: Identifying Vinyl Tape Wrap On Upper And Lower Links
      GTY306957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Vinyl Tape
    8. Install the link of the air outlet control servo motor sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.
      Fig 7: Locating Air Outlet Control Servo Motor Sub-Assembly
      GTY329396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Guide *2 Air Outlet Control Servo Motor Sub-assembly
      *a Air Outlet Control Servo Motor Sub-assembly Slot *b Link Guide Pin (A)
      *c Link Guide Pin (B) - -
    9. Install the guide hole of the air outlet control servo motor sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration.
    10. Temporarily install the screw (up to 4 or 5 threads).
      NOTE:
      • Make sure that the link guide pin (B) is inserted in the air conditioning unit slot.
      • Avoid tilting the air conditioning radiator assembly during installation. This helps to prevent the guide pins from coming out of position.
    11. Lift the air outlet control servo motor sub-assembly slightly to create clearance.
      Fig 8: Lifting Air Outlet Control Servo Motor Sub-Assembly
      GTY321096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Move the air conditioning radiator assembly gear so that alignment holes of the air outlet control servo motor sub-assembly and air conditioning radiator assembly are aligned.
      Fig 9: Aligning Air Outlet Control Servo Motor Sub-Assembly
      GTY335639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Air Outlet Control Servo Motor Sub-assembly Alignment Hole *b Air Conditioning Radiator Assembly Alignment Hole
      *c Air Conditioning Radiator Assembly Gear Alignment Hole - -
    13. Insert a screwdriver into the aligned holes as shown in the illustration.
      Fig 10: Aligning Air Outlet Control Servo Motor Sub-Assembly Using Screwdriver
      GTY321095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Make sure that all the links and gears are in the positions shown in the illustration.
      Fig 11: View Of Air Outlet Control Servo Motor Sub-Assembly Aligned
      GTY335688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Screwdriver is inserted into alignment holes. *b Link guide pin is inserted.
      *c Links is positioned to left side. *d Links is positioned at bottom.
      *e Each link guide pin is inserted in its air outlet control servo motor sub-assembly slot. *f Lever is positioned at top.
      *g Links are in-line. - -
    15. Push the loose fitting air outlet control servo motor sub-assembly into position.
      Fig 12: Pushing Air Outlet Control Servo Motor Sub-Assembly Into Position
      GTY321048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the air outlet control servo motor sub-assembly is fully pushed into position.
      • After pushing the servo into position, keep it in place by holding it until the screws are installed.

      HINT: 

      Push the air outlet control servo motor sub-assembly until a click sound is heard.

    16. Remove the screwdriver.
    17. Fully install the top screw, and then install the air outlet control servo motor sub-assembly with the 2 remaining screws.
      Fig 13: Identifying Air Outlet Control Servo Motor Sub-Assembly And Screws
      GTY316663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    18. Remove the vinyl tape.
  2. INSTALL AIR MIX DAMPER SERVO SUB-ASSEMBLY 
    1. Using the reference point, install the air mix damper servo sub-assembly with the 2 screws.
      Fig 14: Identifying Air Mix Damper Servo Sub-Assembly Component Screws
      GTY304454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Reference Point
  3. INSTALL ASPIRATOR 
    1. Engage the 2 claws and clamp to install the aspirator.
      Fig 15: Locating Aspirator Pipe Claws
      GTY307779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL COOLER AIR HOSE 
  5. INSTALL NO. 1 COOLER THERMISTOR 
    1. Install the No. 1 cooler thermistor as shown in the illustration.
      Fig 16: Installing No. 1 Cooler Thermistor
      GTY308034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Part Length
      A 34.3 mm 1.35 in.
      B 20.9 mm 0.822 in.
      C 50 mm 1.96 in.
      TEXT IN ILLUSTRATION

      *1 From Tank
      *2 Fixed Part
      *3 Sensor Part
      NOTE:
      • Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured.
      • When reusing the evaporator, insert the thermistor one row next to the one that has been used previously (X in the illustration).
      • After inserting the thermistor, do not apply excessive force to the wire.
      • Directly insert the thermistor until the edge of plastic case "a" comes into contact with evaporator "b".
  6. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Install the heater radiator unit sub-assembly as shown in the illustration.
      Fig 17: Installing Heater Radiator Unit Sub-Assembly
      GTY302342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clamp with the screw.
      Fig 18: Locating Heater Radiator Unit Sub-Assembly Claws and Clamps
      GTY258179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 3 claws to install the heater clamp.
      TEXT IN ILLUSTRATION

      *1 Heater clamp
      *2 Clamp
  7. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Engage the 4 claws to install the evaporator insulator as shown in the illustration.
      Fig 19: Locating Evaporator Insulator Claws
      GTY248860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front of Vehicle
      *2 Packing
      NOTE:

      Install the evaporator insulator to the cooler evaporator sub-assembly after making sure that the packing is facing the front of the vehicle as shown in the illustration.

    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.

      Compressor oil

      ND-OIL 8 or equivalent

      Fig 20: Identifying Evaporator Sub-Assembly O-Rings
      GTY253401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 O-rings to the cooler evaporator sub-assembly.
      NOTE:

      Keep the O-rings and O-ring fitting surfaces free from dirt or any foreign matter.

    4. Engage the clamp and install the cooler evaporator sub-assembly with the No. 1 cooler thermistor.
      Fig 21: Locating Cooler Evaporator Sub-Assembly Clamp
      GTY253466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Completely cover the tube with the grommet.

  8. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY 
    1. Install the 6 screws and air conditioning radiator assembly to the blower assembly with the evaporator sub-assembly.
      Fig 22: Identifying Blower Assembly With Screws
      GTY188444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL COOLER EXPANSION VALVE 
    1. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.
      Fig 23: Remove/Install Cooler Expansion Valve Hexagon Bolts
      GTY260881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

  10. INSTALL AIR CONDITIONING HARNESS ASSEMBLY 
    1. Connect each connector.
    2. Engage each clamp to install the air conditioning harness assembly.
      Fig 24: Locating Air Conditioning Harness Assembly Connectors and Clamps
      GTY277623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY 
    1. Engage the guide and 2 claws to install the No. 2 air duct sub-assembly as shown in the illustration.
      Fig 25: Locating No. 2 Air Duct Sub-Assembly Guide and Claws
      GTY295151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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