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 NO. 4 COOLING UNIT PACKING


    1. Install a new No. 4 cooling unit packing in the position shown in the illustration.

      Note

      Check that any remaining No. 4 cooling unit packing has been completely removed from the heater case.

      B004SDJC01
      *A for LHD *B for RHD
      *a Specified Application Position for Packing - -

  2. INSTALL NO. 2 COOLING UNIT BRACKET


    1. B004WAKC01
      *A for LHD
      *B for RHD

      Attach the guide.

    2. Install the No. 2 cooling unit bracket with the screw.

  3. INSTALL NO. 1 COOLING UNIT BRACKET


    1. B004Y14C01
      *A for LHD
      *B for RHD

      Attach the guide.

    2. Install the No. 1 cooling unit bracket with the screw.

  4. INSTALL NO. 1 COOLER THERMISTOR

    Click here

  5. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. B004XIL

      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.

        B004WHBC01
        *a Clamp *b Guide
        *c Guide Pin *d No. 1 Cooler Thermistor Lead Wire
        B004RMI 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.

        B004XRYC01
        *a Clamp *b Guide
        *c Guide Pin *d No. 1 Cooler Thermistor Lead Wire
        B004RMI Secure the lead wire between the guide - -

      2. Install the heater case with the 2 screws.

      3. Attach the clamp.

  6. INSTALL HEATER AIR DAMPER ASSEMBLY


    1. Attach the claw and guide pin.

      B004TFV

      1. Install the heater air damper assembly with the screw.

  7. INSTALL NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. Align the direction of the fitting on the heater case to the fitting on the No. 5 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B004XJ5
    2. B004UZZ

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

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


    1. B004RJH

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

    2. B004VP9

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

    3. B004VSAC01
      *a Matchmarks

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

    4. B004RO0

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

  9. INSTALL NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    1. Align the direction of the fitting on the heater case to the fitting on the No. 6 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B004YF6
    2. B004U43

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

  10. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    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.

      B004SYP
    2. B004XBG

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

  11. 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.

      B004VSE
    2. B004TZR

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

  12. INSTALL NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    1. Align the direction of the fitting on the heater case to the fitting on the No. 5 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B004VYO
    2. B004YPL

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

  13. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    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.

      B004YAZ
    2. B004W8K

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

  14. INSTALL NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. Align the direction of the fitting on the heater case to the fitting on the No. 6 air conditioning radiator damper servo sub-assembly as shown in the illustration.

      B004W3A
    2. B004WB2

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

  15. 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.

      B004VKG
    2. B004WHX

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

  16. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. B004XU6

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

    2. B004W3Z

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

    3. B004YOPC01
      *a Pin

      Align the gear with the position of the pin as shown in the illustration.

    4. B004TSV

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

  17. INSTALL NO. 3 COOLING UNIT BRACKET (for LHD)


    1. B004TC0C01
      *a Guide
      *b Guide pin

      Attach the guide pin, guide and claw.

    2. Install the No. 3 cooling unit bracket with the screw.

  18. INSTALL NO. 1 COOLER COVER


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

    2. B004YVSC01
      B004RMI Install in this Direction

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

  19. 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

    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. B004RRM

      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)

  20. INSTALL AIR CONDITIONING TUBE ASSEMBLY


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

      Note

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

    4. B004XIH

      Using a 4 mm hexagon socket wrench, install the air conditioning 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)

  21. INSTALL NO. 2 COOLER COVER


    1. B004TXA

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

  22. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. for LHD:


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

        B004XWR

    2. for RHD:


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

        B004T26

    3. Attach the 14 connectors.

  23. INSTALL PACKING


    1. Install a new packing as shown in the illustration.

      Note

      Make sure that any remaining packing is completely removed from the air conditioner harness assembly and heater air damper assembly when removing.

      B004Y9GC01
      *A for LHD *B for RHD
      *a Apply packing so that it contacts the heater air damper assembly *b Apply packing so that it wraps around to the rear side of the air conditioner harness assembly
      *c Fold the packing into the inner side (Packing float is acceptable) *d Apply packing to the heater air damper assembly servo motor or to the side of the connector of the air conditioner harness assembly (Packing float is acceptable)
      *e Apply packing to the rear side of the air conditioner harness assembly connector - -

  24. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B004Y8K

      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. B004S45

      Attach the 2 connectors.

    3. Attach the guide.

    4. B004RSDC01
      *A for LHD
      *B for RHD

      Attach the claw to install the heater clamp.

  25. INSTALL NO. 3 COOLING UNIT BRACKET (for RHD)


    1. B004W5X

      Install the No. 3 cooling unit bracket with the screw.

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


    1. B004U4JC01
      *A for LHD
      *B for RHD
      *a Matchmarks
      *b Heater Case Fitting Surface
      *c Quick Heater Claw

      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


      • B004YRKC01
        *a Element
        *b Fin

        Do not hold the quick heater assembly by the element or fin. Also, do not damage the quick heater assembly.

      • Foul odors may occur due to oil adhering to the quick heater assembly.

      • 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 quick heater assembly are aligned.

    2. B004RYUC01
      *A for LHD
      *B for RHD

      Install the quick heater assembly with the screw.

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

    Tech Tips

    Use the same procedure as for the quick heater assembly.

  28. INSTALL COOLING UNIT PARTS


    1. B004UXL

      Install the cooling unit parts.

  29. INSTALL HEATER GROMMET


    1. B004VBJC01
      *A for LHD
      *B for RHD

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

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


    1. B004VW8C01
      *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).

  31. INSTALL DRAIN COOLER HOSE (for Front Passenger Side)


    1. B004V5QC01
      *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).

      Note

      Check that any remaining No. 3 cooling unit packing has been completely removed from the heater case, drain cooler hose (for front passenger side).

  32. INSTALL NO. 2 COOLER UNIT DRAIN HOSE


    1. B004WFL

      Install the No. 2 cooler unit drain hose.

      Note

      Check that any remaining No. 3 cooling unit packing has been completely removed from the No. 2 cooler unit drain hose.

  33. INSTALL NO. 3 COOLING UNIT PACKING


    1. Install a new No. 3 cooling unit packing in the position shown in the illustration.

      Note

      Check that any remaining No. 3 cooling unit packing has been completely removed from the heater case, drain cooler hose (for front passenger side) and No. 2 cooler unit drain hose.

      B004RHYC01
      *A for LHD *B for RHD
      *a Specified Application Position for Packing - -

  34. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)


    1. B004Y71

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

  35. INSTALL ASPIRATOR


    1. B004RAN

      Attach the claw to install the aspirator.

  36. INSTALL BLOWER ASSEMBLY

    Click here