Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2002 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL EVAPORATOR TEMPERATURE SENSOR
Install the sensor with the 2 holders.

Fig 1: Reassembly (1 Of 10)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EVAPORATOR
1. Install the plate to evaporator.
2. Apply water seal to heater case as shown in the illustration.
  
  Fig 2: Reassembly (2 Of 10)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the insulator to heater case.
4. Install the evaporator on the insulator.
  
  Fig 3: Reassembly (3 Of 10)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  If evaporator is replaced, add compressor oil to evaporator.
  
  Add 40 cc (1.4 fl. oz.)
  
  Compressor oil: ND-OIL 8 or equivalent
5. Install the heater cases with the 13 screws.
6. Apply the new packing.
7. Install the grommet to evaporator.
INSTALL HEATER RADIATOR
1. Install 2 new O-rings to heater radiator pipes.
2. Install the heater radiator pipes.
3. Install the 2 clamps with the 2 screws.
4. Install the heater radiator to heater case.
5. Install the 2 plate with 2 screws.
AUTO A/C ONLY: INSTALL BLOWER MOTOR LINEAR CONTROLLER
Install the blower motor linear controller with the 2 screws.
AUTO A/C ONLY: INSTALL AIR MIX SERVOMOTOR
Install the servomotor with 3 screws.

Fig 4: Reassembly (4 Of 10)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET SERVOMOTOR
1. Install the servomotor with the 3 screws.
  
  Fig 5: Reassembly (5 Of 10)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the drain of the plate to the pin and fit the claw.
  
  Fig 6: Reassembly (6 Of 10)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXPANSION VALVE

Lubricate 2 new O-rings with compressor oil and install them to the tube and accessory.
Compressor oil: ND-OIL 8 or equivalent
Install the tube and accessory to the expansion valve.
Apply the new packing.
1. Using a knife, cut off packing paper of packing while peel off the paper, as shown in Fig 7.
  HINT:
  
  Leave the packing paper untaped on the tube side so that the installation bolt hole for remains visible.
  
  Fig 7: Reassembly (7 Of 10)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply the packing.
  
  Fig 8: Reassembly (8 Of 10)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: Do not over tape the packing beyond the expansion valve edge.

Fig 9: Reassembly (9 Of 10)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Lubricate 2 new O-rings with compressor oil and install them to the expansion valve.
Compressor oil: ND-OIL 8 or equivalent
Using a hexagon wrench (5.0 mm, 0.20 in.), with the 2 bolts.

Fig 10: Reassembly (10 Of 10)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.4 N.m (55 kgf.Cm, 48 in.lbf)

NOTE: When installing the expansion valve, take care so that the packing is not jammed with the evaporator.
Peel off remaining packing paper and apply the packing to expansion valve.