Air Conditioning Unit: Reassembly

INSTALL NO. 1 COOLER THERMISTOR
1. If using a new evaporator:
  1. Install the No. 1 cooler thermistor to the evaporator as shown in the illustration.
    
    Fig 1: Identifying No. 1 Cooler Thermistor Dimension
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If reusing the evaporator:
  1. Install the No. 1 cooler thermistor to the evaporator as shown in the illustration.
    
    Fig 2: Identifying No. 1 Cooler Thermistor To Evaporator Dimension
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.
2. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
  Compressor oil: ND-OIL 8 or equivalent
  
  Fig 3: Identifying O-Rings From Cooler Evaporator Sub-Assembly No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the No. 1 cooler evaporator sub-assembly.
  
  Fig 4: Identifying Cooler Evaporator Sub-Assembly No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engage the 5 claws and install the plate cover with the 6 screws.
  
  Fig 5: Locating Plate Cover 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 (35 kgf*cm, 30 in.*lbf)
  
  Fig 6: Identifying Cooler Expansion Valve Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit sub-assembly to the air conditioner radiator assembly.
  
  Fig 7: Identifying Heater Radiator Unit Sub-Assembly From Air Conditioning Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clamp with the screw.
3. Engage the 4 claws and install the heater clamp.
  
  Fig 8: Identifying Heater Clamp Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR
1. Install the air mix control servo motor with the 2 screws.
  
  Fig 9: Identifying Air Mix Control Servo Motor Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVO MOTOR
1. Install the air outlet control servo motor with the 3 screws.
2. Connect the 2 connectors and install the air conditioner harness.
  
  Fig 10: Identifying Air Outlet Control Servo Motor Connector And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN COOLER HOSE
1. Install the drain cooler hose to the air conditioner radiator assembly.
  
  Fig 11: Identifying Drain Cooler Hose From Air Conditioning Radiator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY
1. Engage the 4 claws to install the No. 6 heater to register duct assembly.
  
  Fig 12: Identifying No. 6 Heater To Register Duct Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BLOWER ASSEMBLY
1. Install the blower assembly with the 2 screws.
2. Connect the connector.
  
  Fig 13: Identifying Blower Assembly With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
1. Engage the 2 claws to install the No. 2 air duct sub-assembly.
Fig 14: Installing No. 2 Air Duct Sub-Assembly Screws And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002