AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 COOLER THERMISTOR

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  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. B0086RS

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

    2. Engage the clamp.

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

      B0086UC

    4. Install the 2 screws.

  3. INSTALL COOLER EXPANSION VALVE


    1. 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 8 or equivalent

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

      Note

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

    3. B0089H0

      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 GROMMET SUB-ASSEMBLY


    1. B00889A

      Install the grommet sub-assembly.

  5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B0083GNC01
      B00847Z Install in this Direction

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

  6. INSTALL HEATER CLAMP


    1. B0086S4

      Engage the 3 claws to install the heater clamp.

  7. INSTALL HEATER PIPE GROMMET


    1. B0088U1C01
      *a Reference Point

      Install the heater pipe grommet as shown in the illustration.

      Note

      Install the heater pipe grommet with the arrow facing up.

  8. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for 3 Zone 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. 3 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.

      B0083EIC01
      *a Reference Point - -
    2. B0085J5

      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


    1. for LHD:


      1. B0089GKC01
        *a Reference Point

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

    2. for RHD:


      1. B0086P8C02
        *a Reference Point

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

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


    1. 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.

        B0084GXC01
        *a Reference Point - -
      2. B0086QO

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

    2. 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.

        B0088W1C01
        *a Reference Point - -
      2. B00863CC01
        *a Reference Point

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

  11. INSTALL DRAIN COOLER HOSE


    1. B0087I8C01
      *a Hose Notch
      *b Rib

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

  12. INSTALL HEATER COVER


    1. B00851LC01
      B00847Z Install in this Direction

      Install the heater cover as shown in the illustration.

    2. Install the screw.

  13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. for LHD:


      1. B0085HXC01
        *A for 3 Zone Type

        Engage each clamp.

      2. Connect each connector to install the air conditioning harness assembly.

    2. for RHD:


      1. B0083FW

        Engage each clamp.

      2. Connect each connector to install the air conditioning harness assembly.

  14. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. for LHD:


      1. B0088Q6C01
        B00847Z Install in this Direction

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

      2. Install the air conditioning amplifier assembly with the screw.

      3. Connect the connector.

    2. for RHD:


      1. B0089HXC01
        B00847Z Install in this Direction

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

      2. Install the air conditioning amplifier assembly with the screw.

      3. Connect the connector.

  15. INSTALL BLOWER ASSEMBLY

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  16. INSTALL GROMMET (for Manual Air Conditioning System)


    1. B0086O0

      Engage the 2 claws to install the grommet.

  17. INSTALL ASPIRATOR (for Automatic Air Conditioning System)


    1. B0087MA

      Engage the 2 claws and guide to install the aspirator.

  18. INSTALL NO. 2 AIR DUCT


    1. B0088KW

      Engage the 3 claws.

    2. Install a new No. 2 air duct with the screw.