FRONT AIR CONDITIONING UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. INSTALL BRACKET


    1. for LHD:


      1. B000NWW

        Attach the guide.

      2. Install the bracket with the screw.

      3. B000QFY

        Attach the guide.

      4. Install the bracket with the screw.

    2. for RHD:


      1. B000THP

        Attach the guide.

      2. Install the bracket with the screw.

      3. B000NU8

        Attach the guide.

      4. Install the bracket with the screw.

  2. INSTALL HEATER BRACKET


    1. B000T9GC01
      *A for LHD
      *B for RHD
      B004B1M Insert in this Direction

      Insert the guide as shown in the illustration.

    2. for RHD:


      1. Attach the claw.

    3. Install the heater bracket with the screw.

  3. INSTALL NO. 1 COOLER THERMISTOR

    Click here

  4. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. B000RV6C01
      *A for LHD
      *B for RHD
      B004B1M Install in this Direction

      Install the No. 1 cooler evaporator sub-assembly to the heater case as shown in the illustration.

    2. for LHD:


      1. While inserting the No. 1 cooler thermistor into the guide, insert the guide pin and attach the claw as shown in the illustration.

        B000S0HC01
        *a Clamp *b Guide
        *c Guide Pin *d No. 1 Cooler Thermistor Lead Wire
        B004B1M Secure the lead wire between the guide - -

      2. Install the heater case with the 2 screws.

      3. Attach the clamp.

    3. for RHD:


      1. While inserting the No. 1 cooler thermistor into the guide, insert the guide pin and attach the claw as shown in the illustration.

        B000R1AC01
        *a Clamp *b Guide
        *c Guide Pin *d No. 1 Cooler Thermistor Lead Wire
        B004B1M Secure the lead wire between the guide - -

      2. Install the heater case with the 2 screws.

      3. Attach the clamp.

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


    1. B000PAJ

      Remove the gear of the No. 3 air conditioning radiator damper servo sub-assembly.

    2. B000PCF

      Align the No. 3 air conditioning radiator damper servo sub-assembly with the standard position and install the gear.

    3. B000T38C01
      *a Matchmarks

      Align with the matchmarks on the gear as shown in the illustration.

    4. B000P7W

      Align the guide and install the No. 3 air conditioning radiator damper servo sub-assembly with the 2 screws.

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


    1. Align the direction of the fitting on the heater case to the fitting on the No. 4 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B000RBL
    2. B000RRX

      Install the No. 4 air conditioning radiator damper servo sub-assembly with the 3 screws.

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


    1. Align the direction of the fitting on the heater case to the fitting on the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B000S7TC01
      *A for LHD *B for RHD
    2. B000TJ2C01
      *A for LHD
      *B for RHD

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

  8. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. Align the direction of the fitting on the heater case to the fitting on the No. 2 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B000RWT
    2. B000QPJ

      Install the No. 2 air conditioning radiator damper servo sub-assembly with the 3 screws.

  9. INSTALL NO. 1 COOLER COVER


    1. Remove the vinyl tape from the cooler expansion valve.

    2. B000OHLC01
      B004B1M Install in this Direction

      Install the No. 1 cooler cover to the cooler expansion valve.

  10. INSTALL COOLER EXPANSION VALVE


    1. Remove the vinyl tape from the No. 1 cooler evaporator sub-assembly.

    2. Apply sufficient compressor oil to 2 new O-rings and the fitting surface with the No. 1 cooler evaporator of the cooler expansion valve.

      Compressor Oil
      ND-OIL 11 or equivalent

      Note

      Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

    3. 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.

    4. B000ONR

      Install the cooler expansion valve together with the No. 1 cooler cover.

      Note

      Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  11. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


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

    2. Apply a sufficient amount of compressor oil to 2 new O-rings and the fitting surface of the cooler expansion valve and air conditioning tube and accessory assembly.

      Compressor Oil
      ND-OIL 11 or equivalent

      Note

      Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

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

      Note

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

    4. B000SYH

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

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

      Note

      Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  12. INSTALL NO. 2 COOLER COVER


    1. B000PCQ

      Attach the guide pin and claw to install the No. 2 cooler cover.

  13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. for LHD:


      1. Install the air conditioning harness assembly to the guide.

        B000P0M

      2. Attach the 8 connectors.

      3. B000RN9

        Attach the guide, guide pin and claw.

      4. Install the bracket with the screw.

    2. for RHD:


      1. Install the air conditioning harness assembly to the guide.

        B000OWI

      2. Attach the 8 connectors.

  14. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. for LHD:


      1. B000NWHC01
        B004B1M Insert Straight

        Insert the heater radiator unit sub-assembly into the heater case.

        Note

        Securely insert the heater radiator unit sub-assembly as far as it will go.

      2. B000Q6S

        Attach the claw to install the heater clamp.

    2. for RHD:


      1. B000PXFC01
        B004B1M Insert Straight

        Insert the heater radiator unit sub-assembly into the heater case.

        Note

        Securely insert the heater radiator unit sub-assembly as far as it will go.

      2. B000RVC

        Install the bracket with the screw.

      3. B000RG9

        Attach the claw to install the heater clamp.

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

    Note

    Do not hold the quick heater assembly by the element or fan. Also, do not damage the quick heater assembly. (Foul odors may occur due to oil adhering to the quick heater assembly.)


    1. B000Q0QC01
      *a Matchmarks
      *b Heater Case Fitting Surface
      *c Quick Heater Claw
      B004B1M Insert Straight

      Align the matchmark on the quick heater assembly with the matchmark on the heater case as shown in the illustration, insert the quick heater assembly into the heater case and attach the claw.

      Note

      Check that the heights of the claw fitting surface on the heater case and the claw of the quick heater assembly are aligned.

      Tech Tips

      If the claw of the quick heater assembly are damaged, install the screw.

    2. B000SXM

      Install the quick heater assembly with the screw.

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

    Tech Tips

    Use the same procedure as for the quick heater assembly.

  17. INSTALL COOLING UNIT PARTS


    1. B000OMW

      Install the cooling unit parts.

  18. INSTALL HEATER GROMMET


    1. B000PGHC01
      *A for LHD
      *B for RHD

      Face the heater grommet in the direction of the arrow shown in the illustration and install it.

  19. INSTALL DRAIN COOLER HOSE (for Driver's Side) (for LHD)


    1. B000QLMC01
      *a Protrusion
      *b Cutout

      Align the cutout of the drain cooler hose (for driver's side) with the protrusion of the heater case and install the drain cooler hose (for driver's side).

  20. INSTALL DRAIN COOLER HOSE (for Driver's Side) (for RHD)


    1. B000R04C01
      *a Protrusion
      *b Cutout

      Align the cutout of the drain cooler hose (for driver's side) with the protrusion of the heater case and install the drain cooler hose (for driver's side).

  21. INSTALL DRAIN COOLER HOSE (for Front Passenger Side) (for LHD)


    1. Completely remove any remaining packing on the heater case and drain cooler hose (for front passenger side).

    2. B000OMZC01
      *a Protrusion
      *b Cutout

      Align the cutout of the drain cooler hose (for front passenger side) with the protrusion of the heater case and install the drain cooler hose (for front passenger side).

  22. INSTALL DRAIN COOLER HOSE (for Front Passenger Side) (for RHD)


    1. Completely remove any remaining packing on the heater case and drain cooler hose (for front passenger side).

    2. B000PDVC01
      *a Protrusion
      *b Cutout

      Align the cutout of the drain cooler hose (for front passenger side) with the protrusion of the heater case and install the drain cooler hose (for front passenger side).

  23. INSTALL DRAIN COOLER HOSE (for Connector)


    1. Completely remove any remaining packing on the drain cooler hose (for connector).

    2. B000T45

      Install the drain cooler hose (for connector).

  24. INSTALL PACKING


    1. Install 2 new packings as shown in the illustration.

      Note

      Check that any remaining packing has been completely removed from the heater case, drain cooler hose (for front passenger side) and drain cooler hose (for connector).

      B000SG7C01
      *A for LHD *B for RHD
      *a Specified Application Position for Packing - -

  25. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)


    1. B000RKL

      Install the cooler thermistor (room temperature sensor) to the aspirator.

  26. INSTALL ASPIRATOR


    1. B000PBF

      Attach the claw to install the aspirator.

  27. INSTALL BLOWER ASSEMBLY

    Click here