AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER THERMISTOR


    1. A015YKIE01

      Install the No. 1 cooler thermistor.

      Part Length
      A 48 to 52 mm 1.89 to 2.05 in.
      B 49 mm 1.93 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.

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

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


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

      Compressor oil
      ND-OIL 8 or equivalent
    2. A015YT3

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

    3. A015YIL

      Install the air duct with the 3 claws and 5 screws.

  3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A0163IW

      Install the heater radiator unit sub-assembly.

    2. Install the clamp with the screw.

  4. INSTALL AIR OUTLET CONTROL SERVO MOTOR


    1. A015Z1F

      Engage the claw and install the air outlet control servo motor with the 2 screws.

    2. A0160KNE04

      Temporarily install the drive gear to the air outlet control servo motor. Check that the drive gear and the driven gear are engaged at point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servo motor.

      Note


      • If there is not the same number of gear teeth from the standard position on each gear at the point where the gears are engaged, remove the drive gear, adjust the driven gear, and reinstall the drive gear.

      • The number of gear teeth from the standard position varies according to the stop position of the air outlet control servo motor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.

      • If there is not the same number of gear teeth from the standard position on each gear at the point where the gears are engaged, the air outlet control servo motor may not operate normally.

  5. INSTALL AIR MIX CONTROL SERVO MOTOR


    1. A015ZSX

      Install the air mix control servo motor with the 2 screws.

    2. Install the drive gear to the air mix control servo motor.

    3. Temporarily install the mode damper servo assembly so that the levers fit into each groove.

    4. Slightly lift the air outlet control servo motor. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position from the view indicated by arrow (A).

      A015Z4BE02

      Note


      • If there is not the same number of gear teeth from the standard position on each gear at the point where the 2 gears are engaged, lift the air outlet control servo motor to adjust the driven gear and reinstall the air outlet control servo motor.

      • If there is not the same number of gear teeth from the standard position on each gear at the point where the 2 gears are engaged, the air outlet control servo motor may not operate normally.

    5. Install the servo motor plate with the 4 screws.

    6. A01626Q

      Install the air duct with the 2 screws.

  6. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. A015Z3V

      Install the air conditioning harness assembly.

    2. Connect the connector.

    3. A0161N1

      Connect the 2 connectors and attach the clamp.

  7. INSTALL COOLER EXPANSION VALVE


    1. A0162Z1

      Install the expansion valve.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings on the air conditioning tube assembly.

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

      Torque:
      3.5 N*m  { 35 kgf*cm, 30 in.*lbf }
    5. A015ZX1

      Install a new packing.

  8. INSTALL AIR MIX CONTROL SERVO MOTOR


    1. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Temporarily install the air mix control servo motor.

      Note


      • If there is not the same number of gear teeth from the standard position on each gear at the point where the 2 gears are engaged, remove the air mix control servo motor to adjust the driven gear and reinstall the air mix control servo motor.

      • The number of gear teeth from the standard position varies according to the stop position of the air mix control servo motor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.

      • If there is not the same number of gear teeth from the standard position on each gear at the point where the 2 gears are engaged, the air mix control servo motor may not operate normally.

    2. Install the air mix control servo motor with the 3 screws.

    3. A015ZQJ

      Install the heater piping cover with the 3 screws.

  9. INSTALL COOL AIR BY-PASS CONTROL SERVO MOTOR


    1. A0162VI

      Install the cool air by-pass control servo motor with the 3 screws.

    2. Connect the connector.