Air Conditioning Unit: Reassembly

INSTALL FRONT EVAPORATOR TEMPERATURE SENSOR (See INSTALLATION )
INSTALL DRAIN COOLER HOSE
1. Install the drain cooler hose.
  
  Fig 1: Locating Drain Cooler Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
HINT:

If a new cooler evaporator is installed, add compressor oil to the cooler evaporator as follows.

Compressor oil:

ND-OIL8 or equivalent. Add 40 cc (1.35 fl. oz.)
1. Install the cooler evaporator.
  
  Fig 2: Identifying Cooler Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 4 claws and install the heater case lower.
3. Install the 3 screws.
4. Engage the evaporator temperature sensor connector clamp.
  
  Fig 4: Identifying Evaporator Temperature Sensor Connector Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. Apply sufficient compressor oil (ND-OIL8) to 2 new O-rings and the fitting surface of the cooler expansion valve.
  Compressor oil:
  
  ND-OIL8 or equivalent
2. Install the 2 O-rings onto the cooler evaporator.
3. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.
  Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf)
  
  Fig 5: Identifying Cooler Expansion Valve Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the radiator heater unit onto the air conditioning unit.
  
  Fig 6: Installing Radiator Heater Unit Onto Air Conditioning Unit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 3 clips and install the clamp.
  
  Fig 7: Identifying Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PTC HEATER ASSEMBLY
1. Install the PTC heater with the 2 screws.
2. Engage the clamp.
INSTALL NO. 2 AIR DUCT
1. Engage the 3 claws and install the air duct.
  
  Fig 9: Identifying No 2 Air Duct Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 AIR DUCT
1. Engage the 3 claws and install the air duct.
  
  Fig 10: Identifying No 1 Air Duct Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Engage the claw and install the air mix damper control cable.
  
  Fig 11: Identifying Air Mix Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Engage the claw and install the defroster damper control cable.
  
  Fig 12: Identifying Defroster Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002