FRONT AIR CONDITIONING UNIT

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

Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo sub-assembly are positioned with the correct orientation as shown in the illustration.
Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly upward.
Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.
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.

*a Mode Switching Duct Hole - -
Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.
Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

*a In-line Position - -
Vinyl Tape

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

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.

*1	No. 1 Air Conditioning Radiator Damper Servo Sub-assembly	-	-
*a	Guide	*b	No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Slot
*c	Link Guide Pin (A)	*d	Link Guide Pin (B)

Engage the guide of the air conditioning radiator assembly to the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.
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 link guide pins from coming out of position.
Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

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

*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	-	-

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

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

Push the 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 is fully pushed into position.
- After pushing the No. 1 air conditioning radiator damper servo sub-assembly into position, keep it in place by holding it until the screws are installed.
Tech Tips

Push the No. 1 air conditioning radiator damper servo sub-assembly until a click sound is heard.
Remove the screwdriver.
Fully tighten the top screw, and then install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 screws.
Remove the vinyl tape.

INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

Install the heater radiator unit sub-assembly.
Install the clamp with the screw.
Engage the 3 claws to install the heater clamp.

INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

*a Reference Point

Using the reference points, install the air mix damper servo sub-assembly with the 2 screws.

INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)

Install the quick heater assembly with the 2 screws.
Engage the 2 claws to install the quick heater bracket.
Engage the clamp.
Install the screw.

INSTALL ASPIRATOR (for Manual Air Conditioning System)

Engage the 2 claws to install the aspirator.

INSTALL ASPIRATOR (for Automatic Air Conditioning System)

Engage the 2 claws.
Engage the clamp to install the aspirator.

INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

Engage the guide and 2 claws to install the No. 3 air duct sub-assembly as shown in the illustration.

INSTALL CENTER HEATER TO REGISTER DUCT

Engage the 4 claws to install the center heater to register duct.

INSTALL NO. 1 COOLER THERMISTOR

Click here

INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

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

Note

Keep the O-rings and O-ring fitting surfaces free from dirt and foreign matter.
Engage the clamp and install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor.

Compressor Oil
ND-OIL 8 or equivalent

INSTALL AIR CONDITIONING RADIATOR ASSEMBLY

Engage the 5 claws.
Engage the guide and connect the wire harness.
Install the air conditioning radiator assembly to the blower assembly with cooler evaporator sub-assembly with the 6 screws.

INSTALL COOLER EXPANSION VALVE

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 }

INSTALL AIR CONDITIONING HARNESS ASSEMBLY

for LHD:
1. Engage each clamp to install air conditioning harness assembly.
2. Connect each connector.
for RHD:
1. Engage each clamp to install the air conditioning harness assembly.
  
  *A for Automatic Air Conditioning System - -
2. Connect each connector.

FRONT AIR CONDITIONING UNIT REASSEMBLY