FRONT AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 COOLER THERMISTOR

    Click here

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. B003S7K

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

    2. Connect the connector clamp to the upper heater case.

    3. Attach the claw to install the upper heater case to the lower heater case.

      B003S2F

    4. Install the 2 screws.

  3. INSTALL COOLER EXPANSION VALVE


    1. B003MKI

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

      Compressor Oil
      ND-OIL 8 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. Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 bolts.

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

  4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B003PJAC01
      B003OFB Install in this Direction

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

    2. B003OT0

      Install the heater radiator cover with the 2 screws.

    3. B003J6R

      Attach the claw to install the heater clamp.

    4. B003RGF

      Install the packing.

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


    1. Attach the arm of the No. 2 air conditioning radiator damper servo sub-assembly to the link of the air conditioner radiator assembly as shown in the illustration.

      B003JN2C01
      *a Align as shown - -
    2. B003RSE

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

  6. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


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

      B003R4PC01
      *a Align as shown - -
    2. B003MQY

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

  7. INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)


    1. B003L9X

      Attach the arm of the defroster damper control cable sub-assembly to the link of the blower assembly as shown in the illustration.

    2. Attach the claw to install the defroster damper control cable sub-assembly.

  8. INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)


    1. B003QPI

      Attach the arm of the air mix damper control cable sub-assembly to the link of the blower assembly as shown in the illustration.

    2. Attach the claw to install the air mix damper control cable sub-assembly.

  9. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. B003NTP

      Install the air conditioning amplifier bracket with the 3 screws.

    2. B003NJKC01
      B003OFB Install in this Direction

      for Automatic Air Conditioning System:

      Install the air conditioning amplifier assembly with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    3. B003JISC01
      B003OFB Install in this Direction

      for Manual Air Conditioning System:

      Install the air conditioning amplifier assembly with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  10. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)


    1. Attach the clamp to install the air conditioning harness assembly.

    2. Connect the 4 connectors.

      B003NG4

  11. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. B003OB4

      Attach the claw and clamp to install the air conditioning duct sub-assembly.

  12. INSTALL BLOWER ASSEMBLY

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


    1. B003ODMC01
      B003OFB Install in this Direction

      Install the quick heater assembly with the screw.

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


    1. B003ODMC01
      B003OFB Install in this Direction

      Install the heater cover with the screw.