AIR CONDITIONING UNIT REASSEMBLY

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

    1. 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.

      A011QP7

    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.

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    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.

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      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.

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

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      Text in Illustration
      *a In-line Position - -

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

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      Text in Illustration
      *1 Vinyl Tape

    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.

      A011RFRE02
      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. Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

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    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.

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

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

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      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. Push the loose fitting No. 1 air conditioning radiator damper servo sub-assembly into position.

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      Note

      • Make sure that the No. 1 air conditioning radiator damper servo sub-assembly are fully pushed into position.

      • After pushing the servos into position, keep them in place by holding them 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. Fully install the top screw, and then install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 remaining screws.

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    18. Remove the vinyl tape.

  2. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

    1. Install the heater radiator unit sub-assembly to the air conditioner radiator assembly.

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    2. Install the clamp with the screw.

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    3. Engage the 3 claws and install the heater clamp.

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

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

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      Text in Illustration
      *a Reference Point

  4. INSTALL NO. 1 COOLER THERMISTOR

    1. Install the No. 1 cooler thermistor as shown in the illustration.

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      Part Length
      A 34.3 mm 1.35 in.
      B 20.9 mm 0.82 in.
      C 50 mm 1.96 in.
      Text in Illustration
      *a Fixed Part
      *b Sensor Part

      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. Engage the 2 clamps.

  5. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

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

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      Compressor oil
      ND-OIL 8 or equivalent

    2. Install the No. 1 cooler evaporator sub-assembly to the blower assembly.

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  6. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY

    1. Engage the 2 claws.

    2. Install the blower assembly with cooler evaporator sub-assembly with the 6 screws.

    3. Engage the 3 clamps.

  7. INSTALL COOLER EXPANSION VALVE

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

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

  8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Manual Air Conditioning System)

    1. Engage the 5 clamps to install air conditioning harness assembly.

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    2. Connect the 4 connectors.

    3. Install the heater packing as shown in the illustration.

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

    1. Engage the 5 clamps to install air conditioning harness assembly.

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    2. Connect the 5 connectors.

    3. Install the heater packing as shown in the illustration.

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  10. INSTALL ASPIRATOR

    1. Engage the 2 claws to install the aspirator.

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  11. INSTALL COOLER THERMISTOR HOSE (for Automatic Air Conditioning System)

    1. Engage the clamp to install the cooler thermistor hose.

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  12. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY

    1. Engage the 2 claws and 2 guides to install the No. 6 heater to register duct assembly as shown in the illustration.

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  13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

    1. Engage the 2 claws and guide to install the No. 1 air duct sub-assembly as shown in the illustration.

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