Toyota CH-R Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL NO. 1 COOLER THERMISTOR

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2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Install the No. 1 cooler evaporator sub-assembly with the No. 1 cooler thermistor to the upper heater case.

(b) Engage the clamp.

(c) Engage the claws to install the upper heater case with the No. 1 cooler evaporator sub-assembly to the lower heater case.

(d) Install the 2 screws.

3. INSTALL COOLER EXPANSION VALVE

(a) 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

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

NOTICE:

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

(c) Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N·m {36 kgf·cm, 31 in·lbf}

(d) Install the grommet.

4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

Install in this Direction

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

5. INSTALL HEATER CLAMP

(a) Engage the claws to install the heater clamp.

6. INSTALL HEATER PIPE GROMMET

(a) Install the heater grommet.

7. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Align each gear on the air conditioner 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.

(b) Using the reference points, install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.

8. INSTALL DRAIN COOLER HOSE

(a) Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.

*a Hose Notch *b Rib

9. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Engage the clamps.

(b) Connect each connector to install the air conditioning harness assembly.

10. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

(a) Engage the guide to temporarily install the air conditioning amplifier assembly as shown in the illustration.

Install in this Direction

(b) Install the air conditioning amplifier assembly with the screw.

(c) Connect the connector.

11. INSTALL QUICK HEATER ASSEMBLY

(a) Engage the guide to install the quick heater assembly as shown in the illustration.

Install in this Direction

12. INSTALL NO. 2 HEATER COVER

(a) Engage the claw and guide to install the No. 2 heater cover.

(b) Install the screw.

13. INSTALL BLOWER ASSEMBLY

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14. INSTALL NO. 3 INSTRUMENT PANEL WIRE

(a) Engage the clamps to install the No. 3 instrument panel wire.

(b) Connect the 2 connectors.

15. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY

(a) Engage the claws to install the air conditioning duct sub-assembly.

16. INSTALL NO. 2 AIR DUCT

(a) Engage the claws to remove the No. 2 air duct.

(b) Install the screw.