Air Conditioning Unit: Reassembly

INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator.
  
  Fig 1: Identifying Damper Servomotor Connector Terminals (Air Mix And Air Outlet)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Compressor oil:
  
  ND-OIL or equivalent
2. Install the 2 O-rings on the cooler evaporator.
  
  Fig 2: Identifying Cooler Evaporator O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the air duct with the 3 claws and 5 screws.
Fig 3: Identifying Air Duct Claws And Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the clamp with the screw and install the heater radiator unit.
Fig 4: Identifying Heater Radiator Unit Sub-Assembly Clamp And Screw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVOMOTOR LH
1. Install the air mix control servomotor with the 3 screws.
  
  Fig 5: Locating Air Outlet Control Servomotor LH Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the drive gear to the air outlet control servomotor. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servomotor.
  NOTE:
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the drive gear, adjust the driven gear, and reinstall the drive gear.
  - The number of gear teeth, from the standard position, varies according to the stop position of the air outlet control servomotor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servomotor may not operate normally.
Fig 6: Identifying Drive Gear And Driven Gear Engaged Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVOMOTOR LH
1. Install the air mix control servomotor with the 3 screws.
2. Install the drive gear to the air mix control servomotor.
3. Temporarily install the mode damper servo so that the levers fit into each groove.
  
  Fig 7: Locating Air Mix Control Servomotor LH Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Slightly lift the mode damper servo. Check that the drive gear and driven gear are engaged at a point with the same number of gear teeth from the standard position from the view indicated by arrow (A).
  NOTE:
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, lift the mode damper to adjust the driven gear and reinstall the mode damper servo.
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the mode damper servo may not operate normally.
5. Install the mode damper with the 4 screws.
  
  Fig 8: Identifying Drive Gear And Driven Gear Engaged Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the air duct with the 2 screws.
Fig 9: Identifying Air Duct Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING HARNESS ASSEMBLY
1. Attach the 4 clamps to install the wire harness.
2. Install the A/C harness as shown in the illustration.
  
  Fig 10: Identifying Air Conditioning Harness Assembly Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 2 connectors and attach the clamp.
Fig 11: Locating Air Conditioning Harness Assembly Connectors And Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVOMOTOR RH
1. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Temporarily install the air mix control servomotor.
  NOTE:
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the air mix control servomotor to adjust the driven gear and reinstall the air mix control servomotor.
  - The number of gear teeth, from the standard position, varies according to the stop position of the air mix control servomotor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
  - If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air mix control servomotor may not operate normally.
2. Install the air mix control servomotor with the 3 screws.
Fig 12: Identifying Drive Gear And Driven Gear Engaged Position
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVOMOTOR RH
1. Install the servomotor with the 3 screws.
2. Connect the connector.
Fig 13: Locating Air Outlet Control Servomotor RH Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. Install the cooler expansion valve to the cooler evaporator.
Fig 14: Identifying Cooler Expansion Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING TUBE AND ACCESSORY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the A/C tube.
  Compressor oil:
  
  ND-OIL or equivalent
2. Install the 2 O-rings on the A/C tube.
3. Using a 4 mm hexagon wrench, install the A/C tube with the 2 hexagon bolts.
  Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf)
  
  Fig 15: Identifying A/C Tube Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new packing.
Fig 16: Identifying Packing On A/C Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002