T-SB-0072-09 February 26, 2009

Decreased Air Volume from HVAC Vents

Service
Category Vehicle Interior

Section Heating/Air Conditioning Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2007 – 2009 Tacoma

Introduction

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.

Production Change Information

This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown below.
MODEL DRIVETRAIN PLANT PRODUCTION CHANGE EFFECTIVE VIN

All NUMMI 5TE###2N#9Z593323

Tacoma 2WD 3TM#U#2N#9M070971
TMMBC
4WD 3TM#U#2N#9M007845

Parts Information

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY

87287-04040 SAME Damper, Heater Air 1

N/A 00289-AC897 Delphi RL-897 Compressor Oil As Needed

Warranty Information

OP CODE DESCRIPTION TIME OFP T1 T2

AC9007 R & R Heater Air Damper Door 4.7 87287-04040 62 15

APPLICABLE WARRANTY
• This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.

• Warranty application is limited to correction of a problem based upon a customer’s specific

complaint.

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Decreased Air Volume from HVAC Vents

Required Tools & Equipment

SPECIAL SERVICE TOOLS (SST’S) PART NUMBER QTY

Plastic Pry Tool Set* 00002-06000-01 1

R–134a Refrigerant Recovery/Recycling Machine Robinair ROB34788 (or equivalent) 1

* Essential SST.

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

NOTE
Additional refrigerant service equipment may be ordered by calling Toyota Approved Equipment
(ADE) at 1–800–368–6787.

Repair Procedure

1. Remove the Air Conditioning unit.

Refer to the Technical Information System (TIS), model year repair manual:
• 2007 / 2008 Tacoma
Vehicle Interior – Heating/Air Conditioning – “Air Conditioning Unit: Removal”
2. Remove the 4 bolts and the lower defrost nozzle Figure 1..
assembly.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

3. Remove the 2 bolts and the heater to register Figure 2..

duct.

4. Remove the No. 1 air duct.

A. Remove the bolt.

B. Disengage the 3 claws and remove the air Figure 3.

duct.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

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.

1 Air Inlet Assembly

2 Thermister Clip

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

Figure 6.

6. 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.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

Figure 7.

1 Mode Damper Control Assembly

Figure 8.

1 Temperature Damper Control Assembly

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

7. 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.

Figure 10.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

8. Remove the bolt and the heater pivot. Figure 11..

9. Remove the mode case.

A. Remove the 11 bolts and 1 clip that mount the mode case.
Figure 12.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

10. Remove the evaporator core.

Figure 13.

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.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

Figure 15.

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

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

Figure 17.

13. Install the NEW heater air damper.

Figure 18.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

14. 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.

Figure 20.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

15. Install the evaporator core.

Figure 21.

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 22.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

17. Install the bolt and heater pivot. Figure 23..

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 24.

1 Temperature Damper Control Assembly

19. Install the mode damper control assembly

A. Install the mode damper control assembly.

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

B. Install the 3 bolts on the mode mounting plate.

Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf)
Figure 25.

1 Mode Damper Control Assembly

20. Install the air inlet assembly

A. Install the air inlet assembly.
B. Install the 4 bolts and 1 clip.

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Repair Procedure (Continued)

C. Install the air filter. Figure 26.

D. Connect the cooler thermister clip to the air inlet case.

Figure 27.

1 Air Inlet Assembly

2 Thermister Clip

21. Install the No. 1 Air Duct

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Repair Procedure (Continued)

A. Engage the 3 claws and install the air duct.

B. Install the bolt. Figure 28.

Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf)

22. Install the heater to register duct center with the Figure 29..
2 bolts.
Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf)

23. Install the lower defroster nozzle assembly with Figure 30..
4 bolts.
Torque: 2.0 N*m (20 kgf*cm, 18 ft*lbf)

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Decreased Air Volume from HVAC Vents

Repair Procedure (Continued)

24. Install the air conditioning unit.

NOTE
If compressor oil is removed during A/C system evacuation or removal of the A/C unit, replace
it with Delphi RL-897 part# 00289-AC897.

Refer to the TIS, model year repair manual:

• 2007 / 2008 Tacoma
Vehicle Interior – Heating/Air Conditioning – “Air Conditioning Unit: Installation”
25. Confirm operation with temperature setting at maximum heat.

© 2009 Toyota Motor Sales, USA