Front Cooling Unit: Reassembly: 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

Part	Length
A	34.3 mm	1.35 in.
B	20.9 mm	0.82 in.
C	50 mm	1.96 in.

NOTE:

Be sure to insert the thermistor only once because reinserting it into the same position 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.
  
  Fig 2: Identifying No. 1 Cooler Evaporator Sub-Assembly O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Compressor oil
  
  ND-OIL 11 or equivalent
  NOTE:
  - Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.
  - Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
2. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
3. Install the No. 1 cooler evaporator sub-assembly.
  
  Fig 3: Identifying No. 1 Cooler Evaporator Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engage the clamp.
5. Engage the 5 claws.
  
  Fig 4: Locating No. 1 Cooler Evaporator Sub-Assembly Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the plate cover with the 6 screws.
7. Connect the connector.
INSTALL COOLER EXPANSION VALVE
1. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.
  
  Fig 5: Identifying Cooler Expansion Valve Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf)
INSTALL ASPIRATOR
1. Engage the 2 claws.
  
  Fig 6: Identifying Aspirator Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the clamp and install the aspirator.
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit sub-assembly as shown in the illustration.
  
  Fig 7: Identifying Heater Radiator Unit Sub-Assembly
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INSTALL HEATER CLAMP
1. Install the clamp with the screw.
  
  Fig 8: Identifying Heater Clamp Claws
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2. Engage the 3 claws and install the heater clamp.
INSTALL FRONT AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY
1. Using the reference point, install the front air mix control servo motor sub-assembly with the 2 screws.
  
  Fig 9: Identifying Front Air Mix Control Servo Motor Sub-Assembly Reference Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector.
INSTALL FRONT AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY
1. Install the front air outlet control servo motor sub-assembly with the 3 screws.
  
  Fig 10: Identifying Front Air Outlet Control Servo Motor Sub-Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 connectors.
INSTALL BLOWER ASSEMBLY
1. Engage the 2 claws.
  
  Fig 11: Identifying Blower Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the blower assembly with the 2 screws.
3. Connect the connector.
INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
1. Engage the 3 claws and install the No. 3 air duct sub-assembly as shown in the illustration.
  
  Fig 12: Identifying No. 3 Air Duct Sub-Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ID CODE BOX (IMMOBILISER CODE ECU) . Refer to INSTALLATION - Step 1