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Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2002 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install Heater Radiator 
    1. Push into the heater radiator to the A/C unit case.
    2. Install the 4 screws and 3 clamps.
    3. Install the passenger air duct subassembly.
      4. Fig 1: Installing Heater Radiator
      G01084467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install Expansion Valve 
    1. Coat 4 new O-rings with the compressor oil.
    2. Using a 5 mm hexagon wrench, install the expansion valve to the evaporator with the 2 bolts.
      1. Torque:  3.5 N.m (36 kgf.cm, 31 in.lbf)
      3. Fig 2: Installing Expansion Valve
      G01084468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install Evaporator 
    1. Install the evaporator with the 7 screws.
    2. Wrap the packing.

      If evaporator was replaced, add compressor oil to the compressor.

      1. Add 40 cc (1.4 fl.oz.) 
      2. Compressor Oil:  ND-OIL 8 or equivalent

      3. Fig 3: Installing Evaporator
      G01084469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install Thermistor 
    1. Install the thermistor to the bracket plate as shown in the illustration.
    2. Push into the thermistor to the A/C unit case.
    3. Connect the connector clamp.
      4. Fig 4: Installing Thermistor
      G01084470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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