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Front Evaporator Temperature Sensor: Reassembly

  1. INSTALL FRONT EVAPORATOR TEMPERATURE SENSOR 
    NOTE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted. Insert the sensor within range C shown in the illustration.
    1. Install the sensor as shown in the illustration.
      AREA DIMENSION CHART

      Area Standard Dimension
      a 25 mm (0.984 in.)
      b 154 mm (6.630 in.)
      c 33.3 mm (1.1311 in.)
      d 50 mm (1.969 in.)
      Fig 1: Identifying Air Conditioner Thermistor Installation Dimension
      G04950557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamp.
    Fig 2: Identifying Air Conditioner Thermistor And Clamp
    G04950552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL EVAPORATOR SUB-ASSEMBLY 
    1. Install the evaporator.
    2. Attach the 3 claws to install the front cooling unit case.
    3. Install the 6 screws.
      Fig 3: Locating Front Cooling Unit Case Claws And Screws
      G04950551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install new butyl tape and packing.
    Fig 4: Identifying Butyl Tape And Packing
    G04950560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL AIR CONDITIONER RADIATOR ASSEMBLY 
    1. Install the radiator.
      Fig 5: Locating Radiator
      G04950561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bracket with the screw.
      3. Fig 6: Identifying Air Conditioner Radiator Bracket And Screws
      G04950548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL AIR CONDITIONER HARNESS 
  5. INSTALL PTC HEATER ASSEMBLY (w/ PTC Heater) 
    1. Attach the 3 clamps to install the PTC heater.
    2. Install the 2 screws.
    Fig 7: Identifying PTC Heater Assembly Clamp
    G04950563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT FOOT/DEF SERVO MOTOR LH 
    1. Install the damper servo with the 3 screws.
    2. Connect the connector.
      Fig 8: Locating Damper Servo Screws And Connector
      G04950544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the claw to install the main plate, as shown in the illustration.
    Fig 9: Identifying Main Plate Pin
    G04950565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT FOOT/DEF SERVO MOTOR RH 
    1. Install the damper servo with the 3 screws.
    2. Connect the connector.
      Fig 10: Locating Damper Servo Screws And Connector
      G04950544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the claw to install the main plate.
    Fig 11: Identifying Main Plate Claw
    G04950567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL HOT AIR BYPASS SERVO MOTOR 
    1. Align the protruding parts on the case and cover, install the damper servo with the 2 screws.
    2. Connect the connector.
      3. Fig 12: Locating Damper Servo With Mounting Screws
      G04950568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL AIR MIX SERVO MOTOR LH (Hot) 
    1. Make sure that the rod does not rotate further by trying to rotate it clockwise.
    2. Install the damper servo with the 2 screws.
    3. Connect the connector.
      4. Fig 13: Locating Air Mix Servo Motor LH Screws And Connector
      G04950540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL AIR MIX SERVO MOTOR RH (Hot) 
    1. Make sure that the rod does not rotate further by trying to rotate it clockwise.
    2. Install the damper servo with the 2 screws.
    3. Connect the connector.
    Fig 14: Locating Air Mix Servo Motor RH Screws And Connector
    G04950541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR AIR MIX SERVO MOTOR LH 
    1. Align the protruding parts on the case and cover, install the damper servo with the 2 screws.
    2. Connect the connector.
    Fig 15: Locating Rear Air Mix Servo Motor LH Screws And Connector
    G04950573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR AIR MIX SERVO MOTOR RH 
    1. Align the protruding parts on the case and cover, install the damper servo with the 2 screws.
    2. Connect the connector.
    Fig 16: Locating Rear Air Mix Servo Motor RH Screws And Connector
    G04950574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR MODE SERVO MOTOR LH 
    1. Set the lever onto the stopper, as shown in the illustration.
    2. Install the damper servo with the 2 screws.
    3. Connect the connector.
    Fig 17: Locating Rear Mode Servo Motor LH Screws And Connector
    G04950575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR MODE SERVO MOTOR RH 
    1. Set the lever onto the stopper, as shown in the illustration.
    2. Install the damper servo with the 2 screws.
    3. Connect the connector.
    Fig 18: Locating Rear Mode Servo Motor RH Screws And Connector
    G04950576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL AIR OUTLET SERVO MOTOR LH (Face) 
    1. Install the damper servo with the 2 screws.
    2. Connect the connector.
      Fig 19: Locating Damper Servo Screws And Connector
      G04950533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the lever so that the cutout part engages with a tooth of the gear, and then attach the 3 claws to install the lever.
    Fig 20: Identifying Cutout Part
    G04950578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL AIR OUTLET SERVO MOTOR RH (Face) 
    1. Install the damper servo with the 2 screws.
    2. Connect the connector.
      Fig 21: Identifying Damper Servo Screws And Connector
      G04950535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the lever so that the cutout part engages with a tooth of the gear, attach the claw to install the lever.
      4. Fig 22: Identifying Cutout Part
      G04950580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL AIR MIX SERVO MOTOR LH (Cool) 
    1. Make sure that the rod does not rotate further by trying to rotate it clockwise.
    2. Install the damper servo with the 2 screws.
    3. Connect the connector.
      4. Fig 23: Locating Air Mix Servo Motor LH Connector And Screws
      G04950530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL AIR MIX SERVO MOTOR RH (Cool) 
    1. Make sure that the rod does not rotate further by trying to rotate it clockwise.
    2. Install the damper servo with the 2 screws.
    3. Connect the connector.
    Fig 24: Locating Air Mix Servo Motor RH Connector And Screws
    G04950531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL COOL AIR BYPASS SERVO MOTOR LH 
    1. Set the lever so that the cutout part engages with a tooth of the gear, install the damper servo with the 2 screws.
    2. Connect the connector.
    Fig 25: Identifying Cool Air Bypass Servo Motor Connector And Screws - LH
    G04950528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL COOL AIR BYPASS SERVO MOTOR RH 
    1. Set the lever so that the cutout part engages with a tooth of the gear, install the damper servo with the 2 screws.
    2. Connect the connector.
    Fig 26: Identifying Cool Air Bypass Servo Motor RH Connector And Screws
    G04950529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL AIR DUCT LH 
    1. Attach the 4 claws to install the duct.
    Fig 27: Identifying Air Duct LH Claws
    G04950526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL AIR DUCT RH 
    1. Attach the 4 claws to install the duct.
    Fig 28: Identifying Air Duct RH Claws
    G04950527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL DRAIN COOLER HOSE 
    1. Install the 2 drain hoses, as shown in the illustration.
    Fig 29: Identifying Drain Cooler Hose
    G04950589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL BLOWER ASSEMBLY 
    1. Attach the claw to install the blower unit.
    2. Connect the connector.
    3. Install the screw.
    Fig 30: Identifying Blower Unit Connector And Screw
    G04950524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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