AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 COOLER THERMISTOR

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  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. B004QN2

      Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.

    2. Engage the clamp.

    3. Engage the 10 claws to install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case.

      B004OL0

    4. Install the 2 screws.

  3. INSTALL COOLER EXPANSION VALVE


    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. 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. B004P8S

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

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
    4. B004OWD

      Install the cooling unit parts.

  4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B004ONAC01
      B004PI4 Install in this Direction

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

  5. INSTALL HEATER CLAMP


    1. B004P9E

      Engage the 4 claws to install the heater clamp.

  6. INSTALL HEATER GROMMET


    1. B004PDT

      Install the heater grommet.

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


    1. for LHD:


      1. B004QPPC01
        *a Reference Point

        Using the reference points, install the No. 3 air conditioning radiator damper servo sub-assembly with the 2 screws.

    2. for RHD:


      1. B004OGLC01
        *a Reference Point

        Using the reference points, install the No. 3 air conditioning radiator damper servo sub-assembly with the 2 screws.

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


    1. for Single Air Conditioning System:


      1. Align each gear on the air conditioner radiator assembly as shown in the illustration, and then check that the gears of the No. 2 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.

        B004OQEC01
        *a Reference Point - -
      2. B004QET

        Install the No. 2 air conditioning radiator damper servo sub-assembly with the 3 screws.

    2. for Dual Air Conditioning System:


      1. Align each gear on the air conditioner radiator assembly as shown in the illustration, and then check that the gears of the No. 2 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.

        B004P9LC01
        *a Reference Point - -

      2. Using the reference points, install the No. 2 air conditioning radiator damper servo sub-assembly with the 3 screws.

        B004QXCC01
        *a Reference Point - -

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


    1. for LHD:


      1. B004QI8C01
        *a Link

        Connect the 3 links of the No. 1 air conditioning radiator damper servo sub-assembly to the 3 links of the air conditioning radiator assembly as shown in the illustration.

      2. Install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 screws.

    2. for RHD:


      1. B004QOOC02
        *a Link

        Connect the 2 links of the No. 1 air conditioning radiator damper servo sub-assembly to the 2 links of the air conditioning radiator assembly as shown in the illustration.

      2. Install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 screws.

  10. INSTALL DRAIN COOLER HOSE


    1. B004QWWC01
      *a Hose Notch
      *b Rib

      Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.

  11. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. for LHD:


      1. Engage each clamp.

        B004Q23

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

    2. for RHD:


      1. Engage each clamp.

        B004PRN

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

  12. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. for LHD:


      1. B004P4JC01
        B004PI4 Install in this Direction

        Engage the guide to temporarily install the air conditioning amplifier assembly as shown in the illustration.

      2. Install the air conditioning amplifier assembly with the screw.

      3. Connect the connector.

    2. for RHD:


      1. B004QEFC01
        B004PI4 Install in this Direction

        Engage the guide to temporarily install the air conditioning amplifier assembly as shown in the illustration.

      2. Install the air conditioning amplifier assembly with the screw.

      3. Connect the connector.

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


    1. B004OTWC01
      B004PI4 Install in this Direction

      Install the heater cover with the screw as shown in the illustration.

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


    1. B004PCGC01
      B004PI4 Install in this Direction

      Engage the guide to install the quick heater assembly as shown in the illustration.

  15. INSTALL NO. 2 HEATER COVER (w/ PTC Heater)


    1. B004R0Y

      Engage the guide and claw.

    2. Install the No. 2 heater cover with the screw.

  16. INSTALL BLOWER ASSEMBLY

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  17. INSTALL NO. 3 INSTRUMENT PANEL WIRE (w/ PTC Heater)


    1. B004QPJ

      Engage the 5 clamps to install the No. 3 instrument panel wire.

    2. Connect the 2 connectors.

  18. INSTALL ASPIRATOR


    1. B004OVL

      Engage the 2 claws to install the aspirator.

  19. INSTALL NO. 1 AIR DUCT (for RHD)


    1. B004P6W

      Engage the 3 claws.

    2. Install a new No. 1 air duct with the screw.

  20. INSTALL NO. 2 AIR DUCT (for LHD)


    1. B004QFR

      Engage the 3 claws.

    2. Install a new No. 2 air duct with the screw.