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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (1 Of 3) >> FRONT AIR CONDITIONING UNIT (for HV Model) >> Reassembly [10/2022 - ] >> Procedure

Reassembly [10/2022 - ]: Procedure

  1. INSTALL NO. 1 COOLER THERMISTOR 

    Refer to PROCEDURE - Step 1

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.
      GTY918623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

    2. Engage the 2 clamps.
    3. Engage the 10 claws to install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case.
      GTY918625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 screws.
  3. INSTALL COOLER EXPANSION VALVE 
    1. 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 11 or equivalent

    2. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
      NOTE:

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

    3. Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts.
      GTY943927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.5 N.m (36 kgf/cm, 31 in.lbf) 

  4. INSTALL COOLING UNIT PARTS 
    1. GTY918626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the cooling unit parts.

  5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. GTY935844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction

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

  6. INSTALL HEATER CLAMP 
    1. GTY918579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Engage the 3 claws to install the heater clamp.

  7. INSTALL HEATER GROMMET 
    1. Install the heater grommet as shown in the illustration.
      GTY927618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
      NOTE:

      Install the heater grommet with the arrow facing up.

  8. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY 
    1. Connect the 3 links of the No. 2 air conditioning radiator damper servo sub-assembly to the 3 links of the air conditioning radiator assembly as shown in the illustration.
      GTY944439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Link
    2. Install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.
  9. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY 
    1. Align each gear on the air conditioning radiator assembly as shown in the illustration, and then check that the gears of the No. 1 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.
      GTY941679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point - -
    2. Using the reference points, install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.
      GTY914183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
  10. INSTALL DRAIN COOLER HOSE 
    1. Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.
      GTY871734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose Notch
      *b Rib
  11. INSTALL HEATER COVER 
    1. GTY843633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction

      Install the heater cover as shown in the illustration.

    2. Install the screw.
  12. INSTALL AIR CONDITIONING HARNESS ASSEMBLY 
    1. Engage each clamp.
      GTY1121984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector to install the air conditioning harness assembly.
  13. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Engage the guide to temporarily install the air conditioning amplifier assembly as shown in the illustration.
      GTY937421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the air conditioning amplifier assembly with the screw.
    3. Connect the connector.
  14. INSTALL BLOWER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  15. INSTALL ASPIRATOR 
    1. Engage the 2 claws and guide to install the aspirator.
      GTY918657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY 
    1. Engage the 3 claws.
      GTY918658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new No. 3 air duct sub-assembly with the screw.
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