Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM100000001P8QQ
Model Year Start: 2021 Model: GR Corolla Prod Date Range: [06/2020 - 09/2022]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY; 2021 - 2022 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2020 - 09/2022]

REASSEMBLY

PROCEDURE

1. INSTALL NO. 1 COOLER THERMISTOR

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2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) for HFC-134a (R134a):

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

(b) for HFO-1234yf (R1234yf):

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

NOTICE:

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.

(c) Engage the clamp.

(d) Engage the 10 claws to install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case.

(e) 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.

Refrigerant

Compressor Oil

for Gasoline Model

ND-OIL 12 or equivalent

for HV Model

ND-OIL 11 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}

4. INSTALL COOLING UNIT PARTS

(a) Install the cooling unit parts.

5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

Install in this Direction

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

6. INSTALL HEATER CLAMP

(a) Engage the 3 claws to install the heater clamp.

7. INSTALL HEATER GROMMET

(a) Install the heater grommet as shown in the illustration.

NOTICE:

Install the heater grommet with the arrow facing up.

*a

Reference Point

8. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for 3 Zone Type)

(a) Insert the 3 links of the air conditioning radiator assembly into the grooves of the No. 3 air conditioning radiator damper servo sub-assembly as shown in the illustration.

*a

Link

(b) Install the No. 3 air conditioning radiator damper servo sub-assembly with the 2 screws.

9. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (w/ PTC Heater)

(a) Using the reference points, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

*a

Reference Point

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

(a) 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.

*a

Reference Point

-

-

(2) Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.

(b) 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.

*a

Reference Point

-

-

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

*a

Reference Point

11. 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

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

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

Install in this Direction

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

(a) Engage the claw and 2 guides.

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

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

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

Install in this Direction

(b) Install the screw.

15. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Engage each clamp.

*A

w/ PTC Heater

*B

for 3 Zone Type

*C

for 3 Zone Type or with PTC Heater

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

16. 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.

17. INSTALL REAR NO. 1 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 3 claws to install the rear No. 1 air duct as shown in the illustration.

Install in this Direction

18. INSTALL COVER (w/ Cover)

(a) Engage the 3 claws to install the cover.

19. INSTALL GROMMET (for Manual Air Conditioning System)

(a) Engage the 2 claws to install the grommet.

20. INSTALL ASPIRATOR (for Automatic Air Conditioning System)

(a) Engage the 2 claws and guide to install the aspirator.

21. INSTALL BLOWER ASSEMBLY

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22. INSTALL NO. 2 AIR DUCT

(a) Engage the 3 claws to install a new No. 2 air duct.

(b) Install the screw.

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

(a) Engage the 5 clamps to install the No. 3 instrument panel wire.

(b) Connect the 2 connectors.