AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE


  1. INSTALL EVAPORATOR TEMPERATURE SENSOR (NO. 1 COOLER THERMISTOR)

    Click here

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. 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 11 or equivalent
    2. A00081F

      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. A0009IB

      Install the No. 1 cooler evaporator sub-assembly with evaporator temperature sensor (No. 1 cooler thermistor) to the plate cover.

    4. Engage the clamp.

      Tech Tips

      Completely cover the tube with the grommet.

    5. A0004NT

      Engage the 7 claws.

    6. Install the plate cover with the 6 screws.

  3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A00090F

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

    2. A0004H5

      Install the clamp with the screw.

    3. A0006D7

      Engage the 3 claws to install the heater clamp.

  4. INSTALL QUICK HEATER ASSEMBLY


    1. A000480

      Engage the guide.

    2. Install the quick heater bracket with the screw.

    3. A0009J5

      Insert the quick heater assembly as shown in the illustration.

    4. Install the quick heater assembly with the 2 screws.

    5. Engage the 5 clamps.

  5. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for 3 Zone Type)


    1. A0006BEE05
      Text in Illustration
      *a Reference Point

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

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


    1. A0004T2E11
      Text in Illustration
      *a Reference Point

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

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


    1. A0004C4

      Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo sub-assembly are positioned in the correct orientation as shown in the illustration.

    2. Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air conditioning radiator damper servo sub-assembly upward.

    3. Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.

      A0003LX

    4. 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.

      A0007WIE09
      Text in Illustration
      *a Mode Switching Duct Hole - -

    5. Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.

      A0008RB

    6. Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

      A0004BIE12
      Text in Illustration
      *a In-line Position - -
    7. A000479E11
      Text in Illustration
      *1 Vinyl Tape

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

    8. 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.

      A0005BIE15
      Text in Illustration
      *1 Guide *2 No. 1 Air Conditioning Radiator Damper Servo Sub-assembly
      *a No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Slot *b Link Guide Pin (A)
      *c Link Guide Pin (B) - -

    9. Install the guide hole of the No. 1 air conditioning radiator damper servo sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration.

    10. 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 guide pins from coming out of position.

    11. A00058W

      Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

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

      A0008H8E18
      Text in Illustration
      *a No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Alignment Hole *b Air Conditioning Radiator Assembly Alignment Hole
      *c Air Conditioning Radiator Assembly Alignment Gear Alignment Hole - -
    13. A0004S3

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

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

      A0004DVE12
      Text in 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 air outlet control servo motor slot. *f Lever is positioned at top.
      *g Links are in-line. - -
    15. A00061J

      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.

    16. Remove the screwdriver.

    17. A0007IR

      Fully tighten the top screw, and then install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 remaining screws.

    18. Remove the vinyl tape.

  8. INSTALL COOLER EXPANSION VALVE


    1. A0006P3

      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 }