Toyota Yaris: Air Conditioning Unit / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL AIR DUCT ASSEMBLY

(a) Install the air duct assembly with the 2 nuts.

(b) Install the front panel silencer as shown in the illustration.

(c) Install the 3 retainers.

2. INSTALL NO. 1 COOLER THERMISTOR

Click here

3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.

(b) Engage the guides and claws to install the upper heater case with No. 1 cooler evaporator sub-assembly.

(c) Install the 2 screws.

(d) Engage the guides and clamp.

*a Clamp *b Guide

4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Install the heater radiator unit sub-assembly as shown in the illustration.

5. INSTALL HEATER CLAMP

(a) Engage the claws to install the heater clamp.

6. INSTALL HEATER COVER

(a) Install the heater cover with the screw.

7. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Move the gear of the air conditioner radiator assembly so that the shape of the center gear portion of the air conditioner radiator assembly is aligned with the sensor shaft and output shaft of the No. 1 air conditioning radiator damper servo sub-assembly, and temporarily install the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

(b) Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.

8. INSTALL BLOWER ASSEMBLY

Click here

9. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

(a) Engage the guide to install the air conditioning amplifier assembly.

(b) Install the 2 screws.

10. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Engage the guides.

(b) Connect 3 connectors to install the air conditioning harness assembly.

11. INSTALL DRAIN COOLER HOSE

(a) Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.

*a Rib *b Hose Notch

12. INSTALL COVER

(a) Engage the claws to install the cover.

13. INSTALL NO. 2 AIR DUCT

(a) Engage the claws to install the No. 2 air duct.

(b) Install the screw.

14. INSTALL ASPIRATOR

(a) Engage the claws and guide to install the aspirator.

15. INSTALL COOLER EXPANSION VALVE

(a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 1 cooler evaporator sub-assembly.

Compressor Oil:

ND-OIL 8 or equivalent

(b) Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.

NOTICE:

Keep the O-rings and O-ring fitting surfaces free of foreign matter.

(c) Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N·m {36 kgf·cm, 31 in·lbf}

16. INSTALL COOLER PIPE GROMMET

(a) Install the cooler pipe grommet.

17. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Engage the guides and claws to install the lower defroster nozzle assembly.