Toyota CH-R Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL NO. 1 COOLER THERMISTOR

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2. INSTALL NO. 2 RADIATOR CASE SUB-ASSEMBLY

(a) Install the No. 2 radiator case sub-assembly with the 6 screws.

3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

Install in this Direction

(a) Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor as shown in the illustration.

(b) Connect the connector.

4. INSTALL RADIATOR CASE SUB-ASSEMBLY

(a) Engage the claws and to install the radiator case sub-assembly.

(b) Install the 3 screws.

5. INSTALL HEAT EXCHANGER CASE

(a) Engage the 2 claws and guide, and install the heat exchanger case with the screw.

(b) Install the bracket with the 2 screws.

6. INSTALL COOLER EXPANSION VALVE

(a) Install the grommet.

(b) Sufficiently apply compressor oil to 2 new O-rings and fitting surfaces of the No. 1 cooler evaporator sub-assembly.

Compressor Oil:

VC100YF or equivalent

(c) 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.

(d) Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts.

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

7. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

Install in this Direction

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

(b) Install the 3 screws.

8. INSTALL HEATER CLAMP

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

(b) Install the screw.

9. INSTALL HEATER PIPE GROMMET

(a) Install the heater pipe grommet.

10. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Install the No. 2 air conditioning radiator damper servo sub-assembly as shown in the illustration.

Install in this Direction

(b) Turn the No. 2 air conditioning radiator damper servo sub-assembly to engage the claw as shown in the illustration.

Install in this Direction

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

(a) for Lower RH Side:

(1) Install the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

Install in this Direction

(2) Turn the No. 1 air conditioning radiator damper servo sub-assembly to engage the claw as shown in the illustration.

Install in this Direction

(3) Engage the snap.

(b) for Upper RH Side:

(1) Install the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

Install in this Direction

(2) Turn the No. 1 air conditioning radiator damper servo sub-assembly to engage the claw as shown in the illustration.

Install in this Direction

(c) for Lower LH Side:

(1) Install the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

Install in this Direction

(2) Turn the No. 1 air conditioning radiator damper servo sub-assembly to engage the claw as shown in the illustration.

Install in this Direction

(3) Engage the snap.

(d) for Upper LH Side:

(1) Install the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

Install in this Direction

(2) Turn the No. 1 air conditioning radiator damper servo sub-assembly to engage the claw as shown in the illustration.

Install in this Direction

12. INSTALL NO. 2 COOLER UNIT DRAIN HOSE

(a) Install the No. 2 cooler unit drain hose.

13. INSTALL DRAIN COOLER HOSE

(a) Install the drain cooler hose.

14. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Engage clamps to install the air conditioning harness assembly.

(b) Connect the 5 connectors.

15. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

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

Install in this Direction (1)

Install in this Direction (2)

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

(c) Connect the connector.

16. INSTALL HEATER COVER (w/o PTC Heater)

(a) Install the heater cover with the 2 screws as shown in the illustration.

Install in this Direction

17. INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)

Install in this Direction

(a) Install the quick heater assembly with the 2 screws as shown in the illustration.

18. INSTALL NO. 2 HEATER COVER (w/ PTC Heater)

(a) Install the No. 2 heater cover with the screw.

19. INSTALL BLOWER ASSEMBLY

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20. INSTALL NO. 3 COOLER UNIT DRAIN HOSE

(a) Install the No. 3 cooler unit drain hose.

21. INSTALL NO. 3 INSTRUMENT PANEL WIRE (w/ PTC Heater)

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

(b) Connect the connector.

22. INSTALL COVER (except Cold Area Specification Vehicles)

(a) Engage the claws to install the cover.

23. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY

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

24. INSTALL NO. 2 AIR DUCT

(a) Engage the claws to install the No. 2 air duct as shown in the illustration.

Install in this Direction

(b) Install the screw.

25. INSTALL ID CODE BOX (IMMOBILISER CODE ECU)

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    Disassembly
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