AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL HEATER CASE SUB-ASSEMBLY


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

      B004GOF

  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
      ND-OIL 11 or equivalent
    2. B004EXD

      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. B004FB6

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

    4. Engage the clamp.

    5. Engage the 5 claws.

      B004GWJ

    6. Install the air duct with No. 1 cooler evaporator sub-assembly with the 5 screws.

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


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

      Note

      Make sure that each link guide pin of the No. 3 air conditioning radiator damper servo sub-assembly are inserted in each guide hole of the air conditioning radiator assembly.

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


    1. Using the reference points, install the No. 6 air conditioning radiator damper servo sub-assembly with the 2 screws.

      B004EBPC01
      *1 No. 6 Air Conditioning Radiator Damper Servo Sub-assembly *2 Air Conditioning Radiator Assembly
      *a Reference Point - -

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


    1. B004F1ZC01
      *a Reference Point

      Using the reference points, install the No. 5 air conditioning radiator damper servo sub-assembly with the 2 screws.

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


    1. B004GHLC01
      *a Reference Point

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

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


    1. Using the reference points, install the No. 4 air conditioning radiator damper servo sub-assembly with the 3 screws.

      B004FFUC01
      *1 No. 4 Air Conditioning Radiator Damper Servo Sub-assembly *2 Air Conditioning Radiator Assembly
      *a Reference Point - -

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


    1. B004GSJC01
      *a Reference Point

      Using the reference point, 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. B004EMTC01
      *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.

  11. INSTALL HEATER GROMMET


    1. B004ELN

      Install the heater grommet.

  12. INSTALL NO. 4 COOLING UNIT PACKING


    1. Remove any remaining No. 4 cooling unit packing from the air conditioner radiator assembly.

    2. Remove the release paper from a new No. 4 cooling unit packing.

    3. B004FQ4E01

      Install the No. 4 cooling unit packing as shown in the illustration.

      Dimension Measurement
      A -3.0 to 3.0 mm (0.118 to 0.118 in.)

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


    1. B004FGW

      Engage the 2 claws to install the heater cover as shown in the illustration.

    2. w/ Screw:


      1. B004FII

        Install the screw.

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


    1. B004FUW

      Engage the 2 claws to install the quick heater assembly as shown in the illustration.

    2. w/ Screw:


      1. B004FMC

        Install the screw.

  15. INSTALL HEATER PIPING COVER (for RHD)


    1. B004G9P

      Install the heater piping cover to the heater radiator unit sub-assembly.

  16. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. for LHD:


      1. B004E8D

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

    2. for RHD:


      1. B004ECW

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

      2. Install the screw.

    3. B004FYK

      Engage the 3 claws to install the heater clamp.

  17. INSTALL HEATER PACKING


    1. B004FO2

      Install the heater packing.

  18. INSTALL COOLER EXPANSION VALVE


    1. B004F1C

      Install the cooler expansion valve.

  19. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


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

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

      Compressor Oil
      ND-OIL 11 or equivalent

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

      Note

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

    4. B004GIE

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

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

  20. INSTALL NO. 1 COOLING UNIT PACKING


    1. Remove any remaining No. 1 cooling unit packing from the air conditioner tube and accessory assembly and cooler expansion valve.

    2. Remove the release paper from a new No. 1 cooling unit packing.

    3. B004E6L

      Install the No. 1 cooling unit packing as shown in the illustration.

  21. INSTALL NO. 3 COOLING UNIT PACKING


    1. Remove any remaining No. 3 cooling unit packing from the air conditioner tube and accessory assembly.

    2. Remove the release paper from a new No. 3 cooling unit packing.

    3. B004FXU

      Install the No. 3 cooling unit packing.

  22. INSTALL COOLER PLATE


    1. B004EAK

      Install the cooler plate.

  23. INSTALL NO. 2 COOLING UNIT PACKING


    1. Remove any remaining No. 2 cooling unit packing from the cooler plate.

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

    3. B004G9B

      Install the No. 2 cooling unit packing.

  24. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Engage the clamp.

      B004EK0

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

  25. INSTALL ASPIRATOR PIPE


    1. B004ERW

      Engage the 2 claws to install the aspirator pipe.

  26. INSTALL AIR HOSE


    1. B004FDF

      Install the air hose.

  27. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. B004F91

      Engage the 3 claws to install the lower defroster nozzle assembly.

  28. INSTALL BLOWER ASSEMBLY

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