Air Conditioning Unit: Reassembly

INSTALL NO. 1 COOLER THERMISTOR

Install the No. 1 cooler thermistor as shown in the illustration.

LENGTH SPECIFICATION

Part	Length
A	34.3 mm	1.35 in.
B	20.9 mm	0.823 in.
C	50 mm	1.96 in.

NOTE:

Be sure to insert the thermistor only once because reinserting it 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".

Fig 1: Identifying No 1 Cooler Thermistor Height

INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
  Compressor oil: ND-OIL 8 or equivalent
  
  NOTE: Keep the O-rings and O-ring fitting surfaces clean from dirt or foreign matter.
2. Install the No. 1 cooler evaporator sub-assembly together with the No. 1 cooler thermistor as a set.
3. Engage the clamp.
  
  Fig 2: Identifying No 1 Cooler Evaporator Sub-Assembly And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engage the 4 claws as shown in the illustration.
  
  Fig 3: Identifying Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the lower heater case with the 4 screws.
  
  Fig 4: Locating Lower Heater Case With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. 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 And Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit sub-assembly to the air conditioning unit assembly.
2. Install the clamp with the screw.
  
  Fig 6: Identifying Heater Radiator Unit Sub-Assembly With Screw And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN COOLER HOSE
1. Install the drain cooler hose to the air conditioning unit assembly.
  
  Fig 7: Identifying Drain Cooler Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY (for Automatic Air Conditioning System)
1. Engage the 2 claws and install the air conditioning duct sub-assembly.
  
  Fig 8: Identifying Air Conditioning Duct Sub-Assembly And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
1. Engage the claw.
2. Install the air conditioning amplifier assembly with the screw.
  
  Fig 9: Locating Air Conditioning Amplifier Assembly With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONSOLE MOUNTING BRACKET LH
1. Install the console mounting bracket LH with the screw.
  
  Fig 10: Locating Console Mounting Bracket LH And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONSOLE MOUNTING BRACKET RH
1. Engage the 2 claws and install the console mounting bracket RH as shown in the illustration.
  
  Fig 11: Identifying Console Mounting Bracket RH And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)
1. Connect the connector.
2. Engage each clamp and install the air conditioning harness assembly.
  
  Fig 12: Identifying Air Conditioning Harness And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)
1. Install the quick heater assembly as shown in the illustration.
  
  Fig 13: Identifying Quick Heater Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 screws.
3. Engage each clamp.
  
  Fig 14: Locating Quick Heater Assembly And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)
1. Position the gear of the air mix damper control cable sub-assembly and the unit gear as shown in the illustration, and install the air mix damper control cable sub-assembly.
  
  Fig 15: Installing Air Mix Damper Control Cable Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 HEATER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)
1. Position the gear of the No. 2 heater control cable sub-assembly and the unit link as shown in the illustration, and install the No. 2 heater control cable sub-assembly.
  
  Fig 16: Installing No 2 Heater Control Cable Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR (for TMC Made with Automatic Air Conditioning System)
1. Using the reference point, install the air mix control servo motor with the 3 screws.
2. Connect the connector.
  
  Fig 17: Identifying Air Mix Control Servo Motor With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR (for TMMC, NUMMI Made with Automatic Air Conditioning System)
1. Using the reference point, install the air mix control servo motor with the 2 screws.
2. Connect the connector.
  
  Fig 18: Identifying Air Mix Control Servo Motor With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVO MOTOR (for Automatic Air Conditioning System)
1. Using the reference point, install the air outlet control servo motor with the 3 screws.
2. Connect the connector.
INSTALL IMMOBILISER CODE ECU (w/ Smart Key System) (See INSTALLATION )
INSTALL TRANSPONDER KEY ECU (w/o Smart Key System) (See INSTALLATION )

Fig 19: Identifying Air Outlet Control Servo Motor With Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002