Technical Service Bulletin

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1 INTRODUCTION: Technical Service Bulletin March 3, 2009 Title: DECREASED AIR VOLUME FROM HVAC VENTS Models: Tacoma Some customers may experience decreased air volume from the HVAC vents when the temperature is set to maximum heat. Use the following repair procedure to address the customer concerns. HEATING & AIR CONDITIONING APPLICABILITY: YEAR(S) MODEL(S) ADDITIONAL INFORMATION Tacoma PRODUCTION CHANGE INFORMATION: MODEL DRIVETRAIN PLANT PRODUCTION CHANGE EFFECTIVE VIN All NUMMI 5TE###2N#9Z Tacoma 2WD 3TM#U#2N#9M TMMBC 4WD 3TM#U#2N#9M WARRANTY INFORMATION: OP CODE DESCRIPTION TIME OFP T1 T2 HA9001 R & R Heater Air Damper Door Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 60,000 kilometres, whichever occurs first, from the vehicle s warranty registration date.* * Warranty application is limited to correction of a problem based upon a customer s specific complaint. PARTS INFORMATION: PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY SAME Damper, Heater Air 1 N/A AC897 Delphi RL-897 Compressor Oil As Needed Page 1 of 17

2 REQUIRED TOOLS & EQUIPMENT: ITEM NO. SPECIAL SERVICE TOOLS (SSTS) PART NO. QTY 1 Plastic Pry Tool Set COMPONENT(S) OF KIT/SET MANUFACTURER EQUIPMENT QTY 2 Robinair ROB34200* (or equivalent) R-134a Refrigerant Recovery/Recycling Machine 1 *Essential SST NOTE: Additional SSTs may be ordered by calling SPX/OTC at Page 2 of 17

3 REPAIR PROCEDURE: 1. Remove the Air Conditioning unit. Refer to the Repair Manual within E-TAS / TIS library: Division: Toyota Model: Tacoma Year: 2007 or 2008 Service Category: Vehicle Interior Section: Heating/Air conditioning Keyword: Air Conditioning Unit: Removal 2. Remove the 4 bolts and the lower defrost nozzle assembly. Figure Remove the 2 bolts and the heater to register duct. Figure Remove the No. 1 air duct. A. Remove the bolt. B. Disengage the 3 claws and remove the air duct. Figure 3. Page 3 of 17

4 5. Remove the air inlet assembly. A. Remove the air filter. Figure 4. B. Remove the 4 bolts and 1 clip that mount the air inlet assembly. C. Remove the cooler thermistor clip from the air inlet case. Figure 5. Page 4 of 17

5 Figure Remove the mode damper control assembly. A. Remove the 3 bolts on the mode mounting plate. B. Remove the mode damper control assembly including mode cam, mode mounting plate, and mode control servo. Figure 7. Page 5 of 17

6 Figure Remove the temperature damper control assembly. A. Remove the 3 bolts on the temperature control mounting plate. B. Remove the temperature damper control assembly including temperature control cam, mounting plate, and servo. Figure 9. Page 6 of 17

7 Figure Remove the bolt and the heater pivot. Figure 11. Page 7 of 17

8 9. Remove the mode case. A. Remove the 11 bolts and 1 clip that mount the mode case. Figure Remove the evaporator core. Figure 13. Page 8 of 17

9 11. Remove the top half of the HVAC main case. A. Remove the torx bolt and heater pipe clamp. B. Remove the 2 clips and 15 bolts that mount the top half of the case. Figure 14. Figure 15. Page 9 of 17

10 12. Disengage and remove the heater air damper door from the HVAC main case. Figure 16. Figure 17. Page 10 of 17

11 13. Install the NEW heater air damper. Figure Install the top half of the HVAC main case with 15 bolts and 2 clips. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) A. Install the heater pipe clamp and torx bolt. Figure 19. Page 11 of 17

12 Figure Install the evaporator core. Figure 21. Page 12 of 17

13 16. Install the mode case. A. Install the mode case assembly. B. Install the clip and 11 bolts. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) Figure Install the bolt and heater pivot. Figure 23. Page 13 of 17

14 18. Install the temperature damper control assembly. A. Install the temperature damper control assembly. B. Install the 3 bolts on the temperature mounting plate. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) Figure Install the mode damper control assembly A. Install the mode damper control assembly. B. Install the 3 bolts on the mode mounting plate. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) Figure 25. Page 14 of 17

15 20. Install the air inlet assembly A. Install the air inlet assembly. B. Install the 4 bolts and 1 clip. C. Install the air filter. Figure 26. D. Connect the cooler thermister clip to the air inlet case. Figure 27. Page 15 of 17

16 21. Install the No. 1 Air Duct A. Engage the 3 claws and install the air duct. B. Install the bolt. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) Figure Install the heater to register duct center with the 2 bolts. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) Figure Install the lower defroster nozzle assembly with 4 bolts. Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf) Figure 30. Page 16 of 17

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