AIR CONDITIONING UNIT (for Sedan): Reassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NO. 1 COOLER THERMISTOR
1. Install the sensor onto the evaporator as shown in the illustration.
2. Check that the sensor sticks to the evaporator surface as shown in the illustration (A: Sensor, B: Evaporator).
  NOTE: If reusing the evaporator, do not reinsert the sensor in the same position that it was in before. Insert it within area C, shown in the illustration.
  
  Fig 1: Installing No. 1 Cooler Thermistor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
HINT:

If a new cooler evaporator is installed, add compressor oil to the cooler evaporator as follows.

Compressor oil: ND-OIL8 or the equivalent. Add 40 cc (1.35 fl. oz.)
1. Install the cooler evaporator.
  
  Fig 2: Identifying Cooler Evaporator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 4 claws and install the heater case lower.
3. Install the 3 screws.
  
  Fig 3: Identifying Claws For Heater Case Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engage the cooler thermistor connector.
  
  Fig 4: Identifying Cooler Thermistor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COOLER EXPANSION VALVE
1. Apply sufficient compressor oil (ND-OIL8) to 2 new O-rings and the fitting surface of the cooler expansion valve.
  Compressor oil: ND-OIL8 or the equivalent
2. Install the 2 O-rings onto the cooler evaporator.
3. Using a hexagon wrench 4, install the cooler expansion valve with the 2 hexagon bolts.
  Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf)
  
  Fig 5: Removing Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit onto the air conditioner radiator assembly.
  
  Fig 6: Locating Heater Radiator Unit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 3 clips and install the clamp.
  
  Fig 7: Locating Claws And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 AIR DUCT
1. Engage the 3 claws and install the air duct.
  
  Fig 8: Identifying Claws For No. 2 Air Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 AIR DUCT
1. Engage the 3 claws and install the air duct.
  
  Fig 9: Identifying Claws For Air Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Engage the claw and install the air mix damper control cable.
  
  Fig 10: Identifying Claw For Air Mix Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY
1. Engage the claw and install the defroster damper control cable.
  
  Fig 11: Identifying Claw For Defroster Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002