Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Install the cooler thermistor and cooler evaporator on the case.
2. Attach the temperature sensor clamp.
  
  Fig 2: Identifying Cooler Thermistor Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Attach the 2 claws to install the cover.
4. Install the 4 screws.
  
  Fig 3: Locating Screws And Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 4: Identifying Cooler Expansion Valve And O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator with the clamp and screw.
  
  Fig 5: Identifying Heater Radiator Unit Sub-Assembly Screw And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)
1. Attach the 3 claws to install the cable.
  
  Fig 6: Installing Airmix Damper Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Attach the evaporator case to the blower case.
3. Install the cable with the 3 screws.
  
  Fig 8: Identifying Evaporator Case From Blower Case And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR MIX CONTROL SERVO MOTOR
1. Install the air mix control servo motor with the 3 screws and connect the connector.
  
  Fig 9: Identifying Air Mix Control Servo Motor Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR OUTLET CONTROL SERVO MOTOR
1. Install the air outlet control servo motor with the 3 screws and connect the connector.
  
  Fig 10: Identifying Screws And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Attach the evaporator case to the blower case.
3. Install the 3 screws.
  
  Fig 11: Identifying Evaporator Case From Blower Case And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR DUCT
1. Attach the 2 claws and install the air duct.
  
  Fig 12: Identifying Air Duct And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 HEATER TO REGISTER DUCT
1. Attach the 6 claws and install the heater to register duct.
  
  Fig 13: Identifying Heater To Register Duct And Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002