AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. A01HV0N

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

      Compressor oil
      ND-OIL 11 or equivalent
    2. A01HVXG

      Install the No. 1 cooler evaporator sub-assembly to the blower assembly.

  2. INSTALL NO. 1 COOLER THERMISTOR


    1. A01HVA5E04
      Text in Illustration
      *a Fixed Part
      *b Sensor Part

      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".

    2. Engage the 2 clamps.

  3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A01HSQ7

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

    2. A01HTV1

      Install the clamp with the screw.

    3. A01HSU4

      Engage the 3 claws and install the heater clamp.

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


    1. A01HW0AE01
      Text in Illustration
      *1 Reference Point

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

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


    1. A01HV2G

      Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo sub-assembly are positioned in the correct orientation as shown in the illustration.

    2. Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air conditioning radiator damper servo sub-assembly upward.

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

      A01HT11

    4. 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.

      A01HT94E02
      Text in Illustration
      *a Mode Switching Duct Hole - -

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

      A01HVMA

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

      A01HTR4E02
      Text in Illustration
      *a In-line Position - -
    7. A01HSHZE02
      Text in Illustration
      *1 Vinyl Tape

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

    8. Install the link of the No. 1 air conditioning radiator damper servo sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

      A01HVWXE02
      Text in Illustration
      *1 Guide *2 No. 1 Air Conditioning Radiator Damper Servo Sub-assembly
      *a No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Slot *b Link Guide Pin (A)
      *c Link Guide Pin (B) - -

    9. Install the guide hole of the No. 1 air conditioning radiator damper servo 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 No. 1 air conditioning radiator damper servo sub-assembly slot.

      • Avoid tilting the air conditioning radiator assembly during installation. This helps to prevent the guide pins from coming out of position.

    11. A01HTMB

      Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

    12. Move the air conditioning radiator assembly gear so that alignment holes of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly are aligned.

      A01HV47E02
      Text in Illustration
      *a No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Alignment Hole *b Air Conditioning Radiator Assembly Alignment Hole
      *c Air Conditioning Radiator Assembly Gear Alignment Hole - -
    13. A01HT6L

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

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

      A01HU9ME02
      Text in Illustration
      *a Screwdriver is inserted into alignment holes. *b Link guide pin is inserted.
      *c Link is positioned to left side. *d Link is positioned at bottom.
      *e Each link guide pin is inserted in its No. 1 Air Conditioning radiator damper servo sub-assembly slot *f Lever is positioned at top.
      *g Links are in-line. - -
    15. A01HUCU

      Push the loose fitting No. 1 air conditioning radiator damper servo sub-assembly into position.

      Note


      • Make sure that the No. 1 air conditioning radiator damper servo sub-assembly are fully pushed into position.

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

      Tech Tips

      Push the No. 1 air conditioning radiator damper servo sub-assembly until a click sound is heard.

    16. Remove the screwdriver.

    17. A01HSRK

      Fully install the top screw, and then install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 remaining screws.

    18. Remove the vinyl tape.

  6. INSTALL QUICK HEATER ASSEMBLY


    1. A01HVIU

      Insert the quick heater assembly as shown in the illustration.

    2. A01HTQ8

      Install the 2 screws.

    3. A01HV3M

      Engage the 2 clamps.

    4. A01HU3X

      Engage the guide.

    5. Install the quick heater bracket with the screw.

    6. A01HVVG

      Engage the 2 clamps and install the quick heater assembly.

  7. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY


    1. Engage the 4 claws.

    2. Install the blower assembly with cooler evaporator sub-assembly with the 6 screws.

  8. INSTALL COOLER EXPANSION VALVE


    1. A01HTP5

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

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

  9. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. A01HSUU

      Engage the 5 clamps to install air conditioning harness assembly.

    2. Connect the 5 connectors.

    3. A01HT5H

      Install the heater packing as shown in the illustration.

  10. INSTALL ASPIRATOR


    1. A01HU8A

      Engage the 2 claws to install the aspirator.

  11. INSTALL COOLER THERMISTOR HOSE


    1. A01HVZU

      Engage the clamp to install the cooler thermistor hose.

  12. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A01HSSX

      Engage the 2 claws and 2 guides to install the No. 6 heater to register duct assembly as shown in the illustration.

  13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01HW1A

      Engage the 2 claws and guide to install the No. 1 air duct sub-assembly as shown in the illustration.