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Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2007 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL EVAPORATOR TEMPERATURE SENSOR 
    NOTE: If reusing the evaporator, do not insert the sensor to a location where the sensor was previously inserted. Insert the sensor within range C shown in the illustration.
    1. Install the evaporator temperature sensor as shown in the illustration.
      Fig 1: Installing Evaporator Temperature Sensor
      G04489996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY 
    1. Install the cooler thermistor and cooler evaporator on the case.
    2. Attach the temperature sensor clamp.
      Fig 2: Installing Cooler Thermistor And Cooler Evaporator On Case
      G04489997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the 2 claws to install the cover.
    4. Install the 4 screws.
      Fig 3: Installing Cover
      G04489998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL COOLER EXPANSION VALVE 
    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the hose joint.

      Compressor oil: ND-OIL 8 or equivalent 

    2. Install the 2 O-rings to the cooler evaporator.
    3. Install the cooler expansion valve.
    4. Using a 4 mm hexagon wrench, install the A/C tube with the 2 hexagon bolts.

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

      Fig 4: Installing Cooler Expansion Valve
      G04489999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Install the heater radiator with the clamp and screw.
      Fig 5: Installing Heater Radiator Unit
      G04490000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL AIRMIX DAMPER CONTROL CABLE SUBASSEMBLY (For Manual Air Conditioning System) 
    1. Attach the 3 claws to install the cable.
      Fig 6: Installing Airmix Damper Control Cable
      G04490001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL MODE CONTROL CABLE ASSEMBLY (For Manual Air Conditioning System) 
    1. Attach the 3 claws to install the cable.
      Fig 7: Installing Mode Control Cable Assembly
      G04490002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the evaporator case to the blower case.
    3. Install the cable with the 3 screws.
      Fig 8: Installing Evaporator Case To Blower Case
      G04490003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL AIR MIX CONTROL SERVO MOTOR 
    1. Install the air mix control servo motor with the 3 screws and connect the connector.
      Fig 9: Installing Air Mix Control Servo Motor
      G04490004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL AIR OUTLET CONTROL SERVO MOTOR 
    1. Install the air outlet control servo motor with the 3 screws and connect the connector.
      Fig 10: Installing Air Outlet Control Servo Motor
      G04490005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the evaporator case to the blower case.
    3. Install the 3 screws.
      Fig 11: Installing Evaporator Case To Blower Case
      G04490006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL AIR DUCT 
    1. Attach the 2 claws and install the air duct.
      Fig 12: Installing Air Duct
      G04490007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 3 HEATER TO REGISTER DUCT 
    1. Attach the 6 claws and install the heater to register duct.
      Fig 13: Installing Heater To Register Duct
      G04490008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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