AIR CONDITIONING UNIT REASSEMBLY


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


    1. A01G5VWE07
      Text in Illustration
      *a Fixed Part
      *b Sensor Part

      Install the evaporator temperature sensor (No. 1 cooler thermistor) as shown in the illustration.

      Part Length
      A 34.3 mm 1.35 in.
      B 20.9 mm 0.823 in.
      C 50.0 mm 1.97 in.

      Note


      • Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured.

      • When reusing the evaporator, insert the thermistor one row next to the one that has been used previously (X in the illustration).

      • After inserting the thermistor, do not apply excessive force to the wire.

      • Directly insert the thermistor until the edge of plastic case "a" comes into contact with evaporator "b".

  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 8 or equivalent
    2. A01G6AF

      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. A01G87U

      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. A01G8UI

      Engage the 7 claws.

    6. Install the plate cover with the 6 screws.

  3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A01G7YX

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

    2. A01G6NF

      Install the clamp with the screw.

    3. A01G7JU

      Engage the 3 claws to install the heater clamp.

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


    1. A01G9HS

      Engage the guide.

    2. Install the quick heater bracket with the screw.

    3. A01G8J1

      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. A01G5TXE02
      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. A01G53ME02
      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. A01G6MP

      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.

      A01G9DF

    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.

      A01G7CSE02
      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.

      A01G86Z

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

      A01G4JTE02
      Text in Illustration
      *a In-line Position - -
    7. A01G9LNE02
      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.

      A01G4EQE02
      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. A01G92M

      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.

      A01G9IVE02
      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. A01G5QI

      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.

      A01G7AME02
      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. A01G8V6

      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. A01G9EX

      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. A01G7KG

      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 }