AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE

INSTALL NO. 2 CONDENSER ASSEMBLY
1. Install in this Direction
  
  Install the No. 2 condenser assembly as shown in the illustration.
INSTALL EVAPORATOR TEMPERATURE SENSOR

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INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. Install the No. 1 cooler evaporator sub-assembly with evaporator temperature sensor 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.
4. Install the 2 screws.
5. 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
6. 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.
7. Using a 4 mm hexagon socket wrench, install the connector tube with the 2 hexagon bolts.
  
  Torque:
  
  3.5 N*m { 36 kgf*cm, 31 in.*lbf }
INSTALL COOLER PIPE GROMMET
1. Install the cooler pipe grommet.
INSTALL DRAIN HOSE
1. Install the drain hose.
INSTALL DISCHARGE TEMPERATURE SENSOR

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INSTALL COOLER PACKING

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INSTALL INTERNAL CONDENSER TEMPERATURE SENSOR

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INSTALL COOLER PACKING

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INSTALL NO. 1 DISCHARGE TUBE

Remove the vinyl tape from the No. 1 discharge tube.
Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 1 discharge tube.

Compressor Oil

ND-OIL 11 or equivalent
Install the 2 O-rings to the No. 1 discharge tube.

Note

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

for LHD:

A003MP4C01

*a	Clamp
*b	Guide
	Bolt
	Nut
	Install in this Direction

Install the No. 1 discharge tube with thermistor with the bolt and nut.

Torque:: 5.4 N*m { 55 kgf*cm, 48 in.*lbf }

Engage each guide and each clamp.

for RHD:

A003O1PC02

*a	Clamp
*b	Guide
	Bolt
	Nut
	Install in this Direction

Install the No. 1 discharge tube with thermistor with the bolt and nut.

Torque:: 5.4 N*m { 55 kgf*cm, 48 in.*lbf }

Engage each guide and each clamp.

INSTALL GROMMET
1. *a Reference Point
  
  Install the grommet as shown in the illustration.
  
  Note
  
  Install the grommet with the arrow facing down.
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. Install in this Direction
  
  Install the heater radiator unit sub-assembly as shown in the illustration.
INSTALL HEATER CLAMP
1. Engage the 4 claws to install the heater clamp.
INSTALL HEATER GROMMET
1. *a Reference Point
  
  Install the heater grommet as shown in the illustration.
  
  Note
  
  Install the heater grommet with the arrow facing up.
INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. for LHD:
  1. *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. *a Reference Point
    
    Using the reference points, install the No. 3 air conditioning radiator damper servo sub-assembly with the 2 screws.
INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. for Single Air Conditioning System:
  1. Align each gear on the air conditioning 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.
    
    *a Reference Point - -
  2. 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 conditioning 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.
    
    *a Reference Point - -
  2. *a Reference Point
    
    Using the reference points, install the No. 2 air conditioning radiator damper servo sub-assembly with the 3 screws.
INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. for LHD:
  1. *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. *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.
INSTALL DRAIN COOLER HOSE
1. *a Hose Notch
  
  *b Rib
  
  Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.
INSTALL AIR CONDITIONING HARNESS ASSEMBLY
1. for LHD:
  1. Engage each clamp.
  2. Connect each connector to install the air conditioning harness assembly.
2. for RHD:
  1. Engage each clamp.
  2. Connect each connector to install the air conditioning harness assembly.
INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
1. for LHD:
  1. 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. 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.
INSTALL BLOWER ASSEMBLY

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INSTALL ASPIRATOR
1. Engage the 2 claws to install the aspirator.
INSTALL NO. 1 AIR DUCT (for RHD)
1. Engage the 3 claws.
2. Install a new No. 1 air duct with the screw.
INSTALL NO. 2 AIR DUCT (for LHD)
1. Engage the 3 claws.
2. Install a new No. 2 air duct with the screw.