AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL HEATER CASE SUB-ASSEMBLY


    1. Engage the 10 claws to install a new heater case sub-assembly.

      B002E5Y

  2. INSTALL NO. 1 COOLER THERMISTOR

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  3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


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

      Compressor Oil
      for HFC-134a (R134a)
      ND-OIL 8 or equivalent
      for HFO-1234yf (R1234yf)
      ND-OIL 12 or equivalent
    2. B002ETB

      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. B002ELC

      Install the No. 1 cooler evaporator sub-assembly to the air duct as shown in the illustration.

    4. Engage the claws to install the air duct.

      B002EBW

    5. Install the 5 screws.

  4. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LH Side)


    1. B002DCYC01
      *a Reference Point

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

  5. INSTALL NO. 4 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B002ECSC01
      *a Reference Point

      Using the reference points, install the No. 4 air conditioning radiator damper servo sub-assembly with the 2 screws.

  6. INSTALL NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B002CQX

      Install the No. 6 air conditioning radiator damper servo sub-assembly with the 3 screws.

      Note

      Make sure that each link guide pin of the No. 6 air conditioning radiator damper servo sub-assembly are inserted in each guide hole of the air conditioning radiator assembly.

  7. INSTALL NO. 7 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B002E5WC01
      *a Reference Point

      Using the reference points, install the No. 7 air conditioning radiator damper servo sub-assembly with the 2 screws.

  8. INSTALL NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for 3 Zone Type)


    1. B002DAH

      Install the No. 5 air conditioning radiator damper servo sub-assembly with the 3 screws.

      Note

      Make sure that each link guide pin of the No. 5 air conditioning radiator damper servo sub-assembly are inserted in each guide hole of the air conditioning radiator assembly.

  9. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B002DOMC01
      *a Reference Point

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

  10. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RH Side)


    1. B002EKNC01
      *a Reference Point

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

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


    1. B002CAEC01
      *1 No. 1 Air Conditioning Radiator Damper Servo Sub-assembly
      *2 Air Conditioning Radiator Assembly
      *a Reference Point

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

  12. INSTALL HEATER COVER


    1. B002E7CC01
      *a Heater Case Fitting Surface
      *b heater Cover Claw
      B002C8N Install in this Direction

      Engage the claws to install the heater cover as shown in the illustration.

      Note


      • Firmly push in until a "click" sound is heard.

      • Check that the heights of the claw fitting surface on the heater case and the claw of the heater cover are aligned.

    2. Install the screw.

      Note

      If the claws of the heater cover are damaged, install the heater cover with screw (90159-60431).

      B002CEWC01
      *a Screw Insertion Hole

  13. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B002EKJ

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

    2. B002DB4C01
      B002C8N Install in this Direction

      Engage the claws to install the clamp as shown in the illustration.

  14. INSTALL COOLER EXPANSION VALVE


    1. B002CIG

      Install the cooler expansion valve.

  15. INSTALL AIR CONDITIONER TUBE ASSEMBLY


    1. Remove the vinyl tape from the air conditioner tube assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings and fitting surfaces of the air conditioner tube assembly.

      Compressor Oil
      for HFC-134a (R134a)
      ND-OIL 8 or equivalent
      for HFO-1234yf (R1234yf)
      ND-OIL 12 or equivalent

    3. Install the 2 O-rings to the air conditioner tube assembly.

      Note

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

    4. B002DP0

      Using a 4 mm hexagon wrench, install the air conditioner tube assembly with the 2 hexagon bolts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
    5. B002E21

      Install the butyl tape.

    6. Remove any remaining No. 2 cooling unit packing from the air conditioner tube assembly.

    7. Remove the release paper from a new No. 2 cooling unit packing.

    8. B002EOG

      Install the No. 2 cooling unit packing.

  16. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. except 3 zone type:


      1. Engage the clamp.

        B002ES2

    2. Connect 9 connectors to install the air conditioning harness assembly.

    3. for 3 Zone Type:


      1. Engage the clamp.

        B002CSY

    4. Connect 11 connectors to install the air conditioning harness assembly.

  17. INSTALL ASPIRATOR PIPE


    1. B002EC2

      Engage the claws to install the aspirator pipe.

  18. INSTALL BLOWER ASSEMBLY

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