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FRONT COOLING UNIT REASSEMBLY

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    INSTALL NO. 1 COOLER THERMISTOR


    1. A017C7UE01

      Install the No. 1 cooler thermistor as shown in the illustration.

      Part Length
      A 34.3 mm 1.35 in.
      B 20.9 mm 0.82 in.
      C 50 mm 1.96 in.
      Note:

      • Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured.

      • When reusing the evaporator, insert the thermistor one row next to the one that has been used previously (X in the illustration).

      • After inserting the thermistor, do not apply excessive force to the wire.

      • Directly insert the thermistor until the edge of plastic case "a" comes into contact with evaporator "b".

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    INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. A017F5W

      Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.

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

      Compressor oil
      ND-OIL 8 or equivalent
    3. A017EGL

      Install the No. 1 cooler evaporator sub-assembly.

    4. Engage the clamp.

    5. A017B5I

      Engage the 5 claws.

    6. Install the plate cover with the 6 screws.

    7. Connect the connector.

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    INSTALL COOLER EXPANSION VALVE


    1. A017FGQ

      Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.

      3.5 N*m 36 kgf*cm 31 in.*lbf
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    INSTALL ASPIRATOR (for Manual Air Conditioning System)


    1. A017FBV

      Engage the 2 claws and install the aspirator.

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    INSTALL ASPIRATOR (for Automatic Air Conditioning System)


    1. A017DOA

      Engage the 2 claws.

    2. Engage the clamp and install the aspirator.

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    INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A017F5L

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

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    INSTALL HEATER CLAMP


    1. A017CXV

      Install the clamp with the screw.

    2. Engage the 3 claws and install the heater clamp.

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    INSTALL FRONT AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A017FXJE01

      Using the reference point, install the front air mix control servo motor sub-assembly with the 2 screws.

    2. Connect the connector.

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    INSTALL FRONT AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A017ERE

      Check that the slots, links and gears of the front air outlet control servo motor sub-assembly are positioned in the correct orientation as shown in the illustration.

    2. Face the contact surfaces of the front air outlet control servo motor sub-assembly and air conditioning radiator assembly for the front air outlet control servo motor sub-assembly upward.

    3. A017CY6

      Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.

    4. A017DV0E01

      Rotate the link of the air conditioning radiator assembly to the bottom as shown in the illustration and confirm that the mode switching duct hole is fully closed.

    5. A017B6S

      Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.

    6. A017F12E01

      Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

    7. A017EXXE01

      Wrap the upper and lower links with vinyl tape to hold them in the in-line position.

    8. A017BM9E03

      Install the link of the front air outlet control servo motor sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

    9. Install the guide hole of the front air outlet control servo motor sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration.

    10. Temporarily install the screw (up to 4 or 5 threads).

      Note:

      • Make sure that the link guide pin (B) is inserted in the front air outlet control servo motor sub-assembly slot.

      • Avoid tilting the front air outlet control servo motor sub-assembly during installation. This helps to prevent the guide pins from coming out of position.

    11. A017F3F

      Lift the front air outlet control servo motor sub-assembly slightly to create clearance.

    12. A017DMXE03

      Move the air conditioning radiator assembly gear so that alignment holes of the front air outlet control servo motor sub-assembly and air conditioning radiator assembly are aligned.

    13. A017FO9

      Insert a screwdriver into the aligned holes as shown in the illustration.

    14. A017EZME03

      Make sure that all the links and gears are in the positions shown in the illustration.

    15. A017EW0

      Push the loose fitting front air outlet control servo motor sub-assembly into position.

      Note:

      • Make sure that the front air outlet control servo motor sub-assembly is fully pushed into position.

      • After pushing the servo into position, keep it in place by holding it until the screws are installed.

      Tip:

      Push the front air outlet control servo motor sub-assembly until a click sound is heard.

    16. Remove the screwdriver.

    17. A017C8K

      Fully install the top screw, and then install the front air outlet control servo motor sub-assembly with the 2 remaining screws.

    18. Remove the vinyl tape.

    19. A017DFL

      Connect the 2 connectors.

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    INSTALL BLOWER ASSEMBLY


    1. A017BS3

      Engage the 2 claws.

    2. Install the blower assembly with the 2 screws.

    3. Connect the connector.

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    INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)


    1. A017CNO

      Install the quick heater assembly as shown in the illustration.

    2. Install the 3 screws.

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    INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A017DV8

      Engage the 3 claws and install the No. 3 air duct sub-assembly as shown in the illustration.