AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL HEATER CASE SUB-ASSEMBLY


    1. Engage the 10 claws to install a new heater case sub-assembly.

      B003XZJ

  2. INSTALL NO. 1 COOLER THERMISTOR

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  3. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


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

      Compressor Oil
      ND-OIL 11 or equivalent
    2. B003YL2

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

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    3. B003YI6

      Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the air duct as shown in the illustration.

    4. Engage the clamp.

    5. Engage the 5 claws.

      B003Y92

    6. Install the air duct with No. 1 cooler evaporator sub-assembly with the 5 screws.

  4. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. Install the No. 3 air conditioning radiator damper servo sub-assembly with the 3 screws.

      Note

      Make sure that each link guide pin of the No. 3 air conditioning radiator damper servo sub-assembly are inserted in each guide hole of the air conditioning radiator assembly.

  5. INSTALL NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. Using the reference points, install the No. 6 air conditioning radiator damper servo sub-assembly with the 2 screws.

      B003YDUC01
      *1 No. 6 Air Conditioning Radiator Damper Servo Sub-assembly *2 Air Conditioning Radiator Assembly
      *a Reference Point - -

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


    1. B003YPOC01
      *a Reference Point

      Using the reference points, install the No. 5 air conditioning radiator damper servo sub-assembly with the 2 screws.

  7. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LH Side)


    1. B003YKBC01
      *a Reference Point

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

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


    1. Using the reference points, install the No. 4 air conditioning radiator damper servo sub-assembly with the 3 screws.

      B003YMOC01
      *1 No. 4 Air Conditioning Radiator Damper Servo Sub-assembly *2 Air Conditioning Radiator Assembly
      *a Reference Point - -

  9. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RH Side)


    1. B003YDDC01
      *a Reference Point

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

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


    1. B003XV2C01
      *1 No. 1 Air Conditioning Radiator Damper Servo Sub-assembly
      *2 Air Conditioning Radiator Assembly
      *a Reference Point

      Using the reference points, install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 screws.

  11. INSTALL HEATER GROMMET


    1. B003Y9E

      Install the heater grommet.

  12. INSTALL NO. 4 COOLING UNIT PACKING


    1. Remove any remaining No. 4 cooling unit packing from the air conditioner radiator assembly.

    2. Remove the release paper from a new No. 4 cooling unit packing.

    3. B003YB1E01

      Install the No. 4 cooling unit packing as shown in the illustration.

      Dimension Measurement
      A -3.0 to 3.0 mm (0.118 to 0.118 in.)

  13. INSTALL HEATER COVER (w/o PTC Heater)


    1. B003XR4

      Engage the 2 claws to install the heater cover.

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


    1. B003XYK

      Engage the 2 claws to install the quick heater assembly.

  15. INSTALL HEATER PIPING COVER (for RHD)


    1. B003YOR

      Install the heater piping cover to the heater radiator unit sub-assembly.

  16. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. for LHD:


      1. B003Y5S

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

    2. for RHD:


      1. B003YDB

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

      2. Install the screw.

    3. B003Y59

      Engage the 3 claws to install the heater clamp.

  17. INSTALL HEATER PACKING


    1. B003XQ1

      Install the heater packing.

  18. INSTALL COOLER EXPANSION VALVE


    1. B003XY9

      Install the cooler expansion valve.

  19. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 11 or equivalent

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

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. B003XZQ

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

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

  20. INSTALL NO. 1 COOLING UNIT PACKING


    1. Remove any remaining No. 1 cooling unit packing from the air conditioner tube and accessory assembly and cooler expansion valve.

    2. Remove the release paper from a new No. 1 cooling unit packing.

    3. B003Y1V

      Install the No. 1 cooling unit packing as shown in the illustration.

  21. INSTALL NO. 3 COOLING UNIT PACKING


    1. Remove any remaining No. 3 cooling unit packing from the air conditioner tube and accessory assembly.

    2. Remove the release paper from a new No. 3 cooling unit packing.

    3. B003YCM

      Install the No. 3 cooling unit packing.

  22. INSTALL COOLER PLATE


    1. B003YGV

      Install the cooler plate.

  23. INSTALL NO. 2 COOLING UNIT PACKING


    1. Remove any remaining No. 2 cooling unit packing from the cooler plate.

    2. Remove the release paper from a new No. 2 cooling unit packing.

    3. B003XQV

      Install the No. 2 cooling unit packing.

  24. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Engage the clamp.

      B003XS9

    2. Connect each connector to install the air conditioning harness assembly.

  25. INSTALL ASPIRATOR PIPE


    1. B003Y24

      Engage the 2 claws to install the aspirator pipe.

  26. INSTALL AIR HOSE


    1. B003YDK

      Install the air hose.

  27. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. B003YQV

      Engage the 3 claws to install the lower defroster nozzle assembly.

  28. INSTALL BLOWER ASSEMBLY

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