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Home >> Toyota Truck >> 2005 >> Tacoma 2WD L4-2.7L (2TR-FE) >> Repair and Diagnosis >> Heating and Air Conditioning >> Service and Repair >> Air Conditioning Unit Assembly >> Overhaul - Part 3

Overhaul - Part 3

OVERHAUL (Continued)





81. REMOVE HEATER RADIATOR ASSEMBLY
a. Remove the 3 bolts and temperature mounting plate.




b. Remove the temperature cam.




c. Remove the 8 bolts and heater cover case.




d. Using a torx(R) socket wrench (T30) remove the bolt, clamp and heater radiator assembly.




82. REMOVE BLOWER RESISTOR
a. Remove the 2 bolts and blower resistor.




83. REMOVE BLOWER W/FAN MOTOR SUB-ASSEMBLY
a. Remove the 3 bolts and blower w/fan motor sub-assembly.




84. REMOVE EVAPORATOR CORE
a. Remove the 3 bolts and mode mounting plate.




b. Remove the mode cam.




c. Remove the bolt and heater pivot.




d. Disengage the clip and remove the 11 bolts and mode case




e. Remove the evaporator core.

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

Add 40 cc (1.4 fl.oz.)
Compressor oil: RL-897 or equivalent




85. REMOVE VALVE TO CONNECTOR TUBE
a. Using torx(R) socket wrench (E10), remove the bolt and valve to connector tube.
b. Remove the 2 seal washer from the air conditioning tube assembly.




86. REMOVE EXPANSION VALVE NO.1
a. Using a torx(R) socket wrench (T25), remove the 2 bolts and expansion No.1 valve.
b. Remove the 2 seal washer from the expansion valve No.1.




87. REMOVE COOLER THERMISTOR SENSOR
a. Disengage the 2 clamps and remove the cooler thermistor sensor.

88. REMOVE COOLER UNIT DRAIN HOSE NO.1
89. INSTALL COOLER UNIT DRAIN HOSE NO.1




90. INSTALL COOLER THERMISTOR SENSOR
a. Engage the 2 clamps and install the cooler thermistor sensor.




91. INSTALL EXPANSION VALVE NO.1
a. Apply sufficient compressor oil to 2 new seal washers and the fitting surface of the expansion No.1 valve.

Compressor oil: RL-897 or equivalent

b. Install the 2 seal washers onto the expansion valve No.1.
c. Using a torx(R) socket wrench (T25), install the expansion No.1 valve with the 2 bolts.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)




92. INSTALL VALVE TO CONNECTOR TUBE
a. Apply sufficient compressor oil to 2 new seal washers and fitting surface of the valve to connector tube.

Compressor oil: RL-897 or equivalent

b. Install the 2 seal washers onto the valve to connector tube.
c. Using a torx(R) socket wrench (E10), install the air conditioning tube assembly with the bolt.

Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)




93. INSTALL EVAPORATOR CORE
a. Attach evaporator side seal to both sides of the evaporator.




b. Attach evaporator top seal to the upper side and evaporator bottom seal to the lower side of the evaporator.




c. Align and apply expansion valve seal to the periphery of the expansion valve protrusions on the back side of the expansion valve.




d. Align and attach the 2 different seals to the evaporator inlet and outlet pipes.




e. Install the evaporator core.




f. Install the mode case with the clip and 11 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




g. Install the heater pivot with the bolt.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




h. Install the mode cam.




i. Install the mode mounting plate with the 3 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




94. INSTALL BLOWER W/FAN MOTOR SUB-ASSEMBLY
a. Install the blower w/ fan motor sub-assembly with the 3 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




95. INSTALL BLOWER RESISTOR
a. Install the blower resistor with the 2 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




96. INSTALL HEATER RADIATOR ASSEMBLY
a. Apply heater core short seal to both sides of the heater core.




b. Apply heater core long seal to the upper and lower sides of the heater core.




c. Apply heater core header seal to the right side of the heater core.




d. Using a torx(R) socket wrench (T30), install the heater radiator assembly.

Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)




e. Install the heater cover case with the 8 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




f. Install the temperature cam.




g. Install the temperature mounting plate with the 3 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




97. INSTALL AIR INLET CONTROL SERVOMOTOR
a. Install the air inlet control servomotor with the 2 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




98. INSTALL AIR MIX CONTROL SERVOMOTOR
a. Install the air mix control servomotor with the 2 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




99. INSTALL MODE CONTROL SERVOMOTOR
a. Install the mode control servomotor with the 3 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




100. INSTALL AIR DUCT NO.1
a. Engage the 3 claws and install the air duct No.1.
b. Install the bolt.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




101. INSTALL HEATER TO REGISTER DUCT CTR
a. Install the heater to register duct CTR with the 2 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




102. INSTALL DEFROSTER NOZZLE ASSEMBLY LWR
a. Install the defroster nozzle assembly LWR with the 4 bolts.

Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)




103. INSTALL AIR CONDITIONING UNIT ASSEMBLY
a. Provisionally install the air conditioning unit assembly.
b. Insert the bracket hook into the holes of the reinforcement bracket, and provisionally install the reinforcement.
c. Install the instrument panel reinforcement with the 7 bolts.
d. Install the 2 caps.




e. Install the 5 bolts.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

NOTE: Tighten the bolts in the sequence order shown in the illustration to install the air conditioner unit assembly.

f. Install the 2 nuts.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)




g. Engage the 20 clamps.




h. Connect the connector.
i. Connect the 2 airbag connectors.
j. Install the 3 bolts.




k. Engage the 2 clamps and connect the 6 connectors to the air conditioning unit assembly.




104. INSTALL AIR-CONDITIONER AMPLIFIER ASSEMBLY
a. Install the air-conditioner amplifier assembly with the nut.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)

b. Connect the connector.




105. INSTALL TRANSPONDER KEY ECU ASSEMBLY
a. Install the transponder key ECU assembly with the nut.
b. Connect the connector.




106. INSTALL DRIVER SIDE JUNCTION BLOCK
a. Install the driver side junction block assembly with the 2 nuts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

b. Install the bracket with the 2 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

107. INSTALL ECM
108. INSTALL PARKING BRAKE CONTROL LEVER ASSEMBLY (LEVER TYPE PARKING BRAKE)
109. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
110. INSTALL STEERING COLUMN ASSEMBLY
111. INSTALL STEERING COLUMN HOLE COVER




112. INSTALL INSTRUMENT PANEL BRACE MOUNTING BRACKET NO.1
a. Install the instrument panel brace mounting bracket No.1 RH with the bolt and nut.




b. Install the instrument panel brace mounting bracket No.1 LH with the bolt and nut.




113. INSTALL AIR DUCT ASSEMBLY
a. Engage the 3 claws and install the air duct assembly.




114. INSTALL AIR DUCT ASSEMBLY HEATER
a. Engage the 4 claws and remove the air duct assembly heater.
b. Engage the clip.




115. INSTALL AIR DUCT REAR NO.1 (DOUBLE CAB)
a. Engage the 2 claws and install the air duct rear No.1.
b. Put the floor carpet back down.




116. INSTALL AIR DUCT REAR NO.2 (DOUBLE CAB)
a. Engage the 2 claws and install the air duct rear No.2.
b. Put the floor carpet back down.




117. INSTALL HEATER TO REGISTER DUCT NO.3
a. Install the heater to register duct No. 3 with the nut.




118. INSTALL HEATER TO REGISTER DUCT NO.1
a. Install the heater to register duct No. 1 with the nut.

119. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY W/PASSENGER AIRBAG ASSEMBLY
120. CONNECT PASSENGER AIRBAG CONNECTOR
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