Air Conditioning Unit: Reassembly

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL COOLER EVAPORATOR SUB-ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator.
  Compressor oil: ND-OIL 8 or equivalent
2. Install the 2 O-rings on the cooler evaporator.
Fig 1: Installing O-Rings On Cooler Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EVAPORATOR TEMPERATURE SENSOR
1. Install the evaporator temperature sensor 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 insert the sensor to the position that it had been inserted before. Insert it between position C shown in the illustration.
  
  Fig 2: Installing Evaporator Temperature Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cooler evaporator on the heater case with the 7 screws.
  
  Fig 3: Installing Cooler Evaporator On Heater Case With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the plate with the 2 screws.
Fig 4: Installing Plate With Screws
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INSTALL COOLER EXPANSION VALVE
1. Install the cooler expansion valve to the cooler evaporator.
Fig 5: Installing Cooler Expansion Valve To Cooler Evaporator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CONDITIONING TUBE ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube.
  Compressor oil: ND-OIL 8 or equivalent
  
  Fig 6: Applying Compressor Oil To 2 New O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 4 mm hexagon wrench, install the air conditioning tube with the 2 hexagon bolts.
  Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf)
  
  Fig 7: Installing Air Conditioning Tube With Hexagon Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cover with the claw and 2 screws.
Fig 8: Installing Cover With Claw And Screws
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INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install the heater radiator unit.
  
  Fig 9: Installing Heater Radiator Unit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Attach the 3 claws and install the clamp.
Fig 10: Attaching Claws And Installing Clamp
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INSTALL HEATER PIPING COVER
1. Attach the 3 claws and install the heater piping cover.
Fig 11: Attaching Claws And Installing Heater Piping Cover
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INSTALL AIR MIX CONTROL SERVO MOTOR
1. Install the air mix control servo motor with the 2 screws.
Fig 12: Installing Air Mix Control Servo Motor With Screws
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INSTALL AIR OUTLET CONTROL SERVO MOTOR
1. Install the air outlet control servo motor with the 3 screws.
Fig 13: Installing Air Outlet Control Servo Motor With Screws
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INSTALL AIR DUCT
1. Attach the 2 claws and install the air duct.
Fig 14: Attaching Claws And Installing Air Duct
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INSTALL NO. 1 COOLER UNIT DRAIN HOSE
1. Install the cooler unit drain hose.
Fig 15: Installing Cooler Unit Drain Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002