AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 COOLER THERMISTOR

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  2. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY


    1. A004X04

      Apply a sufficient amount of compressor oil to 2 new O-rings and the fitting surfaces.

      Compressor oil
      ND-OIL 11 or equivalent

    2. Install the 2 O-rings to the cooler evaporator subassembly.

      Note


      • Keep the O-rings and O-ring fitting surfaces free from dirt or any foreign matter.

      • 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 a leakage of electric power.

    3. A004ZSF

      Engage the clamp and install the cooler evaporator sub-assembly with the No. 1 cooler thermistor.

      Tech Tips

      Completely cover the tube with the grommet.

    4. A004XJA

      Engage the 4 claws.

    5. Install the lower heater case with the 4 screws.

    6. A004XIK

      Install the packing.

  3. INSTALL COOLER EXPANSION VALVE


    1. A004WJ4

      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 }

  4. INSTALL DRAIN COOLER HOSE


    1. A004YWYE02
      Text in Illustration
      *a Matchmark

      Install the drain cooler hose as shown in the illustration.

  5. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A004XNS

      Engage the 2 guides to install the air conditioning amplifier assembly as shown in the illustration.

    2. Install the screw.

  6. INSTALL CONSOLE MOUNTING BRACKET RH


    1. A004ZMP

      Engage the 2 claws and install the console mounting bracket RH.

  7. INSTALL CONSOLE MOUNTING BRACKET LH


    1. A0050AN

      Install the console mounting bracket LH with the screw.

  8. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A004YQ2

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

    2. A004X2DE01
      Text in Illustration
      *1 Clamp

      Install the clamp with the screw.

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


    1. for LHD:


      1. A004WKN

        Install the quick heater assembly as shown in the illustration.

      2. A004YCG

        Install the 2 screws.

      3. Engage the 3 clamps.

    2. for RHD:


      1. A004X94

        Install the quick heater assembly as shown in the illustration.

      2. A004XGV

        Install the 2 screws.

      3. Engage the 3 clamps.

  10. INSTALL AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A004Z5PE04
      Text in Illustration
      *a Reference Point

      Using the reference point, install the air outlet control servo motor sub-assembly with the 3 screws.

  11. INSTALL NO. 2 AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A004VJ2E03
      Text in Illustration
      *a Reference Point

      Using the reference point, install the No. 2 air mix control servo motor sub-assembly with the 3 screws.

  12. INSTALL AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A004VD0E04
      Text in Illustration
      *a Reference Point

      Using the reference point, install the air mix control servo motor sub-assembly with the 3 screws.

  13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Connect each connector.

      A004WJ2

    2. Engage each clamp to install the air conditioning harness assembly.

  14. INSTALL ASPIRATOR (for LHD)


    1. A004ZUD

      Engage the 2 claws and install the aspirator.

  15. INSTALL ASPIRATOR (for RHD)


    1. A004ZR8

      Engage the 2 claws and install the aspirator.

  16. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for LHD)


    1. A00508U

      Engage the 2 claws to install the No. 2 air duct sub-assembly.

  17. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A004W7E

      Engage the 2 claws to install the No. 1 air duct sub-assembly.

  18. INSTALL BLOWER ASSEMBLY (w/o PTC Heater)

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  19. INSTALL BLOWER ASSEMBLY (w/ PTC Heater)

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