Air Conditioning Unit: Reassembly

INSTALL NO. 1 COOLER THERMISTOR

Install the No. 1 cooler thermistor as shown in the illustration.

Fig 1: Identifying No. 1 Cooler Thermistor

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

COOLER THERMISTOR LENGTH SPECIFICATION

Part	Length
A	34.3 mm	1.35 in.
B	20.9 mm	0.823 in.
C	50 mm	1.96 in.

NOTE:

Be sure to insert the thermistor only once because reinserting it will not allow it to be firmly secured.
When reusing the evaporator, insert the thermistor one row next to the one that has been used previously (X in the illustration).
After inserting the thermistor, do not apply excessive force to the wire.
Directly insert the thermistor until the edge of plastic case "a" comes into contact with evaporator "b".

INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
  Compressor oil:
  
  ND-OIL 8 or equivalent
  
  NOTE: Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.
2. Install the No. 1 cooler evaporator sub-assembly together with the No. 1 cooler thermistor as a set.
3. Engage the clamp.
  
  Fig 2: Identifying No. 1 Cooler Evaporator Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engage the 4 claws as shown in the illustration.
  
  Fig 3: Identifying No. 1 Cooler Evaporator Sub-Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the lower heater case with the 4 screws.
Fig 4: Locating No. 1 Cooler Evaporator Sub-Assembly 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 (36 kgf*cm, 31 in.*lbf)
  
  Fig 5: 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 conditioning unit assembly.
2. Install the clamp with the screw.
Fig 6: Identifying Heater Radiator Unit Sub-Assembly Screw And Clamp
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INSTALL DRAIN COOLER HOSE
1. Install the drain cooler hose to the air conditioning unit assembly.
Fig 7: Identifying Drain Cooler Hose
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INSTALL CONSOLE MOUNTING BRACKET LH
1. Install the console mounting bracket LH with the screw.
Fig 8: Locating Console Mounting Bracket LH Screw
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INSTALL CONSOLE MOUNTING BRACKET RH
1. Engage the 2 claws to install the console mounting bracket RH.
Fig 9: Identifying Console Mounting Bracket RH Claws
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INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)
1. Install the quick heater assembly as shown in the illustration.
  
  Fig 10: Installing Quick Heater Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 screws.
3. Engage each clamp.
Fig 11: Identifying Quick Heater Assembly Screws And Clamp
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INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Position the gear of the air mix damper control cable sub-assembly and the unit gear as shown in the illustration, and install the air mix damper control cable sub-assembly.
Fig 12: Installing Air Mix Damper Control Cable Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 HEATER CONTROL CABLE SUB-ASSEMBLY
1. Position the gear of the No. 2 heater control cable sub-assembly and the unit link as shown in the illustration, and install the No. 2 heater control cable sub-assembly.
INSTALL TRANSPONDER KEY ECU (See INSTALLATION )

Fig 13: Installing No. 2 Heater Control Cable Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002