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Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL NO. 1 COOLER THERMISTOR 
    1. Install the No. 1 cooler thermistor.
      NO. 1 COOLER THERMISTOR DESCRIPTION

      Part Length
      A 48 to 52 mm 1 89 to 2 05 in
      B 49 mm 1 93 in
      Fig 1: Identifying No. 1 Cooler Thermistor
      G05755358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured.
      • After inserting the thermistor, do not apply excessive force to the wire.
  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the No. 1 cooler evaporator sub-assembly

      Compressor oil: 

      ND-OIL 8 or equivalent 

    2. Install the 2 O-rings on the cooler evaporator sub-assembly.
      Fig 2: Identifying Cooler Evaporator O-Rings
      G05297861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the air duct with the 3 claws and 5 screws.
      Fig 3: Identifying Air Duct With Claws And Screws
      G05755360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Install the heater radiator unit sub-assembly.
    2. Install the clamp with the screw.
      Fig 4: Identifying Clamp With Screw
      G05755354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL AIR OUTLET CONTROL SERVO MOTOR 
    1. Engage the claw and install the air outlet control servo motor with the 2 screws.
      Fig 5: Locating Air Outlet Control Servo Motor With Screws
      G05755352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the drive gear to the air outlet control servo motor. 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 servo motor
      NOTE:
      • If there is not the same number of gear teeth from the standard position on each gear at the point where the 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 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 gears are engaged, the air outlet control servo motor may not operate normally.
        Fig 6: Identifying Drive Gear And Air Outlet Control Servo Motor Engaged Position
        G05306960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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 7: Locating Air Mix Control Servo Motor With Screws
      G05755353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 8: Identifying Gear Engagement
      G05755365Courtesy 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 2 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 2 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.
    6. Install the air duct with the 2 screws.
      Fig 9: Identifying Air Duct With Screws
      G05297855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL AIR CONDITIONING HARNESS ASSEMBLY 
    1. Install the air conditioning harness assembly.
    2. Connect the connector.
      Fig 10: Locating Air Conditioning Harness Assembly Connector
      G05755349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 connectors and attach the clamp.
      Fig 11: Locating Connectors
      G05755368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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 

      Fig 12: Identifying Cooler Expansion Valve
      G05297847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 O-rings on the air conditioning tube assembly.
    4. Using a 4 mm hexagon wrench, install the air conditioning tube assembly with the 2 hexagon bolts.

      Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) 

    5. Install a new packing
      Fig 13: Identifying New Packing
      G05755346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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 14: Locating Air Mix Control Servo Motor
      G05755371Courtesy 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 2 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 2 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
    3. Install the heater piping cover with the 3 screws.
      Fig 15: Locating Heater Piping Cover With Screws
      G05755372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL COOL AIR BY-PASS CONTROL SERVO MOTOR 
    1. Install the cool air by-pass control servo motor with the 3 screws.
    2. Connect the connector
      Fig 16: Locating Cool Air By-Pass Control Servo Motor With Screws
      G05297849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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