Air Conditioning Unit: Reassembly

INSTALL COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator sub-assembly.
  Compressor oil:
  
  ND-OIL 8 or equivalent
2. Install the 2 O-rings on the cooler evaporator sub-assembly.
  
  Fig 1: Identifying Cooler Evaporator O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the air duct with the 3 claws and 5 screws.
  
  Fig 2: Identifying Air Duct With Claws And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit sub-assembly.
2. Install the clamp with the screw.
  
  Fig 3: Identifying Heater Radiator Unit Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVO MOTOR
1. Install the air outlet control servo motor with the 2 screws.
  
  Fig 4: Locating Air Outlet Control Servo Motor From Servo Motor Plate
  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 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 servo motor may not operate normally.
    
    Fig 5: Checking Drive Gear And Driven Gear Engaged Point
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR
1. Install the air mix control servo motor with the 2 screws.
2. Install the drive gear to the air mix control servo motor.
3. Temporarily install the mode damper servo assembly so that the levers fit into each groove.
4. Slightly lift the air outlet control servo motor. 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 from the view indicated by arrow (A).
  
  Fig 6: Locating Air Mix Control Servo Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 7: Identifying Engaged Position Drive Gear And Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 air outlet control servo motor to adjust the driven gear and reinstall the air outlet control servo motor.
  - 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 servo motor may not operate normally.
5. Install the air outlet control servo motor with the 4 screws.
INSTALL AIR CONDITIONING HARNESS ASSEMBLY
1. Attach the 4 clamps to install the air conditioning harness assembly.
2. Install the air conditioning harness as shown in the illustration.
  
  Fig 8: Attaching Clamps To Air Conditioning Harness Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 2 connectors and attach the clamp.
  
  Fig 9: Attaching Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. Install the expansion valve.
2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assembly.
  Compressor oil:
  
  ND-OIL 8 or equivalent
3. Install the 2 O-rings on the air conditioning tube assembly.
4. Using a hexagon wrench 4 mm, install the air conditioning tube assembly with the 2 hexagon bolts.
  Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf)
  
  Fig 10: Identifying Cooler Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install a new packing.
INSTALL AIR MIX CONTROL SERVO MOTOR
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 servo motor.
  
  Fig 11: Identifying Cooler Expansion Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 servo motor to adjust the driven gear and reinstall the air mix control servo motor.
  - The number of gear teeth from the standard position varies according to the stop position of the air mix control servo motor. 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 servo motor may not operate normally.
2. Install the air mix control servo motor with the 3 screws.
INSTALL AIR OUTLET CONTROL SERVO MOTOR
1. Install the air outlet control servo motor with the 3 screws.
2. Connect the connector.
  
  Fig 12: Locating Air Outlet Control Servo Motor And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002