Toyota Tundra Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL COOLER EXPANSION VALVE

(a) Sufficiently apply compressor oil to 4 new O-rings and the fitting surface of the hose joint. Compressor oil: ND-OIL 12 or equivalent

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

(c) Install the 2 O-rings to the tube and accessory.

(d) Install the cooler expansion valve and tube and accessory to the No. 1 cooler evaporator sub-assembly.

(e) Using a 4 mm hexagon wrench, install the 2 bolts.

Torque:

3.5 N·m {36 kgf·cm, 31 in·lbf}

2. INSTALL NO. 1 COOLER THERMISTOR

3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Install the No. 1 cooler evaporator sub-assembly to the blower case (front side).

(b) Install the blower case (back side).

(c) Install the 6 screws and attach the 3 claws.

(d) Install the No. 2 cooling unit packing and No. 1 cooling unit packing as shown in the illustration.

4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Install the heater radiator unit sub-assembly.

(b) Attach the 3 claws to install the heater clamp.

(c) Install the plate with the 3 screws.

5. INSTALL COOLING UNIT DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

(a) Install the cooling unit damper servo sub-assembly with the 3 screws as shown in the illustration.

(b) Connect the connector.

6. INSTALL BLOWER DAMPER SERVO SUB-ASSEMBLY

(a) Install the blower damper servo sub-assembly with the 3 screws.

(b) Connect the connector.

7. INSTALL BLOWER UPPER CASE SUB-ASSEMBLY

(a) Attach the 2 claws to install the blower upper case sub-assembly.

(b) Install the 3 screws.

8. INSTALL DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

(a) Install the damper servo sub-assembly with the 3 screws.

(b) Connect the connector.

9. INSTALL NO. 1 DAMPER SERVO SUB-ASSEMBLY

(a) Set the No. 1 damper servo sub-assembly so that the cutout part engages with the tooth of the gear, and attach the claw to install the No. 1 damper servo sub-assembly.

*a	Air Conditioning Unit Side	*b	Damper Servo Side
*c	Cutout	*e	Tooth
	Rotate lever in direction of arrow until it stops	-	-

(b) Install the 4 screws and connect the 2 connectors.

10. INSTALL AIR DUCT

(a) Install the air duct with the 2 screws.

11. INSTALL BLOWER WITH FAN MOTOR SUB-ASSEMBLY

(a) Install the blower with fan motor sub-assembly with the 3 screws.

12. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

13. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

(a) Install the No. 3 air duct sub-assembly with the screw.

14. INSTALL CLEAN AIR FILTER

(a) Install the clean air filter as shown in the illustration.

15. INSTALL AIR FILTER COVER PLATE

(a) Attach the 2 claws to install the air filter cover plate.

16. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Attach the 4 claws to install the No. 1 air duct sub-assembly.

17. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Attach the 4 claws to install the lower defroster nozzle assembly.