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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 (2 Of 3) >> Rear Air Conditioning Unit >> Reassembly [12/2019 - ] >> Procedure

Reassembly [12/2019 - ]: Procedure

  1. INSTALL REAR EVAPORATOR SUB-ASSEMBLY 
    1. Install the rear evaporator sub-assembly as shown in the illustration.
      GTY846815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
      NOTE:

      When the rear evaporator sub-assembly is removed, make sure to install a new one. The rear evaporator sub-assembly cannot be reused.

  2. INSTALL NO. 2 AIR CONDITIONING HARNESS ASSEMBLY 
    1. Engage the 2 claws.
      GTY916110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear cooling unit cover LH with the 12 screws.
      GTY943361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage each clamp to install the No. 2 air conditioning harness assembly.
      GTY916112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL REAR AIR MIX DAMPER SERVO SUB-ASSEMBLY 
    1. Using the reference points, install the rear air mix damper servo sub-assembly with the 2 screws.
      GTY890815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
    2. Connect the connector.
  4. INSTALL REAR MODE DAMPER SERVO SUB-ASSEMBLY 
    1. Using the reference points, install the rear mode damper servo sub-assembly with the 2 screws.
      GTY877972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
    2. Connect the connector.
  5. INSTALL BLOWER MOTOR CONTROL 
    1. Install the blower motor control with the 2 screws.
      GTY916118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR BLOWER MOTOR WITH FAN SUB-ASSEMBLY 
    1. Install the rear blower motor with fan sub-assembly with the 3 screws.
      GTY916120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Replace the rear blower motor with fan sub-assembly if it has been dropped or subjected to a severe impact.

  7. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. Install the heater radiator unit sub-assembly as shown in the illustration.
      GTY931450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the 2 bushes.
      GTY943364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the clamp with the screw.
      GTY916125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 2 guides.
      GTY916126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the bracket with the 3 screws.
  8. INSTALL REAR COOLING UNIT EXPANSION VALVE 
    1. Remove the vinyl tape from the rear cooling unit expansion valve and rear evaporator sub-assembly.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the rear evaporator sub-assembly.
      Refrigerant Compressor Oil
      for Gasoline Model ND-OIL 12 or equivalent
      for HV Model ND-OIL 11 or equivalent
    3. Install the 2 O-rings to the rear evaporator sub-assembly.
      NOTE:

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

    4. Using a 4 mm hexagon socket wrench, install the rear cooling unit expansion valve with the 2 hexagon bolts.
      GTY916127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.1 N.m (32 kgf/cm, 27 in.lbf) 

    5. Install the grommet.
      GTY943365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the 3 claws to install the plate.
      GTY916130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL AIR CONDITIONING HOSE AND ACCESSORY 
    1. Remove the vinyl tape from the air conditioning hose and accessory and rear cooling unit expansion valve.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning hose and accessory.
      Refrigerant Compressor Oil
      for Gasoline Model ND-OIL 12 or equivalent
      for HV Model ND-OIL 11 or equivalent
    3. Install the 2 O-rings to the air conditioning hose and accessory.
      NOTE:

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

    4. Insert the hose joint into the fitting hole securely and install the bolt.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

      GTY916132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the air conditioning hose and accessory and engage the 2 clips within the area shown in the illustration.
      GTY884046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Inlet
      *c Outlet
      *d Inlet:
      Marking (White)
      Outlet:
      Marking (Yellow)
      *e Clip Installation Angle (60°)
      NOTE:

      Do not apply excessive force to the air conditioning hose and accessory.

    6. Install the air conditioning hose and accessory with the 2 screws.
      GTY943376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL AIR DUCT PACKING 
    1. Install a new air duct packing as shown in the illustration.
      GTY930214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cold Point
  11. INSTALL DRAIN COOLER HOSE 
    1. Align the hose notch with the rear cooling unit assembly rib as shown in the illustration and install the drain cooler hose.
      GTY846600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose Notch
      *b Rear Cooling Unit Assembly Rib
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