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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) >> FRONT AIR CONDITIONING UNIT (for Gasoline Model) >> Reassembly [11/2023 - ] >> Procedure

Reassembly [11/2023 - ]: Procedure

  1. INSTALL NO. 1 COOLER THERMISTOR 

    Refer to PROCEDURE - Step 1

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. w/o Stop And Start System:
      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.
    2. w/ Stop And Start System:
      1. Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.
        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.

        GTY918622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 12 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 

    Refer to PROCEDURE - Step 4

  5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  6. INSTALL HEATER CLAMP 

    Refer to PROCEDURE - Step 6

  7. INSTALL HEATER GROMMET 

    Refer to PROCEDURE - Step 7

  8. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 8

  9. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY 
    1. for Single Type:
      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.
        GTY938892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Reference Point - -
      2. Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.
        GTY918589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Dual Type:
      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 

    Refer to PROCEDURE - Step 10

  11. INSTALL HEATER COVER 

    Refer to PROCEDURE - Step 11

  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 

    Refer to PROCEDURE - Step 13

  14. INSTALL BLOWER ASSEMBLY 

    See step  1

  15. INSTALL ASPIRATOR (for Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 15

  16. INSTALL GROMMET (for Manual Air Conditioning System) 
    1. Engage the 2 claws to install the grommet.
      GTY918654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

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