AIR CONDITIONING UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

A bolt without a torque specification is shown in the standard bolt chart Click here.

PROCEDURE


  1. INSTALL MAX HOT BYPASS SERVO MOTOR (Cool) (for LHD)


    1. Install the max hot bypass servo motor (cool) with the 3 screws.

    2. A000V2TE02
      Text in Illustration
      *1 Pin

      Attach the claw to install the lever, as shown in the illustration.

  2. INSTALL MAX HOT BYPASS SERVO MOTOR (Cool) (for RHD)


    1. Install the max hot bypass servo motor (cool) with the 3 screws.

    2. A000U4WE01
      Text in Illustration
      *1 Pin

      Attach the claw to install the lever, as shown in the illustration.

  3. INSTALL COOLER EXPANSION VALVE


    1. Sufficiently apply compressor oil to 4 new O-rings, the fitting surface of the evaporator sub-assembly and the air conditioner tube.

      Compressor oil
      ND-OIL8 or equivalent

    2. Install the 2 O-rings to the evaporator sub-assembly.

    3. Install the 2 O-rings to the air conditioner tube assembly.

    4. Install the cooler expansion valve and air conditioner tube assembly to the evaporator sub-assembly.

    5. Using a 4 mm hexagon wrench, install the 2 hexagon bolts.

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

  4. INSTALL NO. 1 COOLER THERMISTOR

    Click here

  5. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. Install the No. 1 evaporator sub-assembly to the front cooling unit case (front side).

    2. Attach the 3 claws to install the front cooling unit case (back side) to the front cooling unit case (front case).

    3. Install the 6 screws.

    4. A000VOBE01

      Attach the hook to install the bracket to the air conditioner tube assembly, and install the holding spring.

    5. Install a new packing to the bracket.

    6. A000YB2

      Tightly wrap a new No. 2 cooling unit packing to prevent exposure of the expansion valve and air conditioner tube assembly, and then wrap a new No. 3 cooling unit packing over the No. 2 cooling unit packing.

  6. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A000ZL0

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

    2. Install the clamp with the screw.

    3. A000ZZ1

      Install a new packing to the clamp.

  7. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

  8. INSTALL QUICK HEATER ASSEMBLY

    Click here

  9. INSTALL AIR OUTLET SERVO MOTOR LH (Foot/Def)


    1. Install the front air outlet servo motor LH (foot/def) with the 3 screws.

    2. Connect the connector.

    3. A000UPOE01
      Text in Illustration
      *1 Pin

      Attach the claw to install the main plate as shown in the illustration.

  10. INSTALL AIR OUTLET SERVO MOTOR RH (Foot/Def)


    1. Install the air outlet servo motor RH (foot/def) with the 3 screws.

    2. Connect the connector.

    3. A000ZG8E01
      Text in Illustration
      *1 Pin

      Attach the claw to install the main plate.

  11. INSTALL MAX HOT BYPASS SERVO MOTOR (Hot)

    A000ZJ2E03
    Text in Illustration
    *1 Alignment Marks

    1. When reusing the max hot air bypass servo motor (hot):

      Align the moving parts and air conditioning unit as shown in the illustration and install the max hot air bypass servo motor (hot) with the 2 screws.

    2. A000TCJE01
      Text in Illustration
      *1 Protruding Part

      When using the new max hot air bypass servo motor (hot):

      Align the protruding parts on the case and cover, and then install the max hot air bypass servo motor (hot) with the 2 screws.

    3. Connect the connector.

  12. INSTALL AIR MIX SERVO MOTOR LH (Hot)


    1. A000WE8

      Make sure that the rod does not rotate further by trying to rotate it clockwise.

    2. Install the air mix servo motor LH (Hot) with the 2 screws.

    3. Connect the connector.

  13. INSTALL AIR MIX SERVO MOTOR RH (Hot)


    1. A000W9K

      Make sure that the rod does not rotate further by trying to rotate it clockwise.

    2. Install the air mix servo motor RH (Hot) with the 2 screws.

    3. Connect the connector.

  14. INSTALL AIR MIX SERVO MOTOR LH (Front A/C Rear Air Flow)

    A000Z8IE03
    Text in Illustration
    *1 Alignment Marks

    1. When reusing the air mix servo motor LH (front A/C rear air flow):

      Align the moving parts and air conditioning unit as shown in the illustration and install the air mix servo motor LH (front A/C rear air flow) with the 2 screws.

    2. A000UORE01
      Text in Illustration
      *1 Protruding Part

      When using the new air mix servo motor LH (front A/C rear air flow):

      Align the protruding parts on the case and cover, and then install the air mix servo motor LH (front A/C rear air flow) with the 2 screws.

    3. Connect the connector.

  15. INSTALL AIR MIX SERVO MOTOR RH (Front A/C Rear Air Flow)

    A000U7YE02
    Text in Illustration
    *1 Alignment Marks

    1. When reusing the air mix servo motor RH (front A/C rear air flow):

      Align the moving parts and air conditioning unit as shown in the illustration and install the air mix servo motor RH (front A/C rear air flow) with the 2 screws.

    2. A000WLZE01
      Text in Illustration
      *1 Protruding Part

      When using the new air mix servo motor RH (front A/C rear air flow):

      Align the protruding parts on the case and cover, and then install the air mix servo motor RH (front A/C rear air flow) with the 2 screws.

    3. Connect the connector.

  16. INSTALL AIR OUTLET SERVO MOTOR LH (Front A/C Rear Air Flow)

    A000X72E01
    Text in Illustration
    *1 Alignment Marks

    1. When reusing the air outlet servo motor LH (front A/C rear air flow):

      Align the moving parts and air conditioning unit as shown in the illustration and install the air outlet servo motor LH (front A/C rear air flow) with the 2 screws.

    2. A000XFME01
      Text in Illustration
      *1 Matchmark

      When using the new air outlet servo motor LH (front A/C rear air flow):

      Align the lever with the matchmark as shown in the illustration.

    3. Install the air outlet servo motor LH (front A/C rear air flow) with the 2 screws.

    4. Connect the connector.

  17. INSTALL AIR OUTLET SERVO MOTOR RH (Front A/C Rear Air Flow)

    A000T8SE04
    Text in Illustration
    *1 Alignment Marks

    1. When reusing the air outlet servo motor RH (front A/C rear air flow):

      Align the moving parts and air conditioning unit as shown in the illustration and install the air outlet servo motor RH (front A/C rear air flow) with the 2 screws.

    2. A000W5PE01
      Text in Illustration
      *1 Stopper

      Set the lever to the stopper as shown in the illustration.

    3. Install the air outlet servo motor RH (front A/C rear air flow) with the 2 screws.

    4. Connect the connector.

  18. INSTALL AIR OUTLET SERVO MOTOR LH (Face)


    1. Install the air outlet servo motor LH (face) with the 2 screws.

    2. Connect the connector.

    3. A000U7EE04
      Text in Illustration
      *1 Alignment Marks

      When reusing the air outlet servo motor LH (face):

      Align the moving parts and air conditioning unit as shown in the illustration and install the lever.

    4. A000VL0E01
      Text in Illustration
      *1 Cutout Part

      When using the new air outlet servo motor LH (face):

      Set the lever so that the cutout part engages with a tooth of the gear, and then attach the 3 claws to install the lever.

  19. INSTALL AIR OUTLET SERVO MOTOR RH (Face)


    1. Install the air outlet servo motor RH (face) with the 2 screws.

    2. Connect the connector.

    3. A000V24E02
      Text in Illustration
      *1 Alignment Marks

      When reusing the air outlet servo motor RH (face):

      Align the moving parts and air conditioning unit as shown in the illustration and install the lever.

    4. A000TELE01
      Text in Illustration
      *1 Cutout Part

      When using the new air outlet servo motor RH (face):

      Set the lever so that the cutout part engages with a tooth of the gear, and then attach the claw to install the lever.

  20. INSTALL AIR MIX SERVO MOTOR LH (Cool)


    1. A000USP

      Make sure that the rod does not rotate further by trying to rotate it clockwise.

    2. Install the air mix servo motor LH (cool) with the 2 screws.

    3. Connect the connector.

  21. INSTALL AIR MIX SERVO MOTOR RH (Cool)


    1. A000UBN

      Make sure that the rod does not rotate further by trying to rotate it clockwise.

    2. Install the air mix servo motor RH (cool) with the 2 screws.

    3. Connect the connector.

  22. INSTALL COOL AIR BYPASS SERVO MOTOR LH

    A000XGUE03

    1. When reusing the cool air bypass servo motor LH:

      Align the moving parts and air conditioning unit as shown in the illustration and install the damper servo with the 2 screws.

      Text in Illustration
      *1 Alignment Marks
    2. A000WYD

      When using the new cool air bypass servo motor LH:

      Set the lever so that the cutout part engages with a tooth of the gear, and then install the cool air bypass servo motor LH with the 2 screws.

    3. Connect the connector.

  23. INSTALL COOL AIR BYPASS SERVO MOTOR RH

    A000XP4E03

    1. When reusing the cool air bypass servo motor RH:

      Align the moving parts and air conditioning unit as shown in the illustration and install the damper servo with the 2 screws.

      Text in Illustration
      *1 Alignment Marks
    2. A000U86

      When using the new cool air bypass servo motor RH:

      Set the lever so that the cutout part engages with a tooth of the gear, and then install the cool air bypass servo motor RH with the 2 screws.

    3. Connect the connector.

  24. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. Attach the 4 claws to install the No. 1 duct sub-assembly.

  25. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. Attach the 4 claws to install the No. 2 duct sub-assembly.

  26. INSTALL BLOWER ASSEMBLY

    Click here