FRONT AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER THERMISTOR


    1. A01CG39E01

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

      Part Length
      A 34.3 mm 1.35 in.
      B 20.9 mm 0.822 in.
      C 50 mm 1.96 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. A01CEAM

      Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.

      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 from dirt or any foreign objects.

    3. A01CFB5

      Install the No. 1 cooler evaporator sub-assembly.

    4. Engage the clamp.

    5. A01CBQT

      Engage the 5 claws.

    6. Install the plate cover with the 6 screws.

    7. Connect the connector.

  3. INSTALL COOLER EXPANSION VALVE


    1. A01CE9V

      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 }

  4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A01CGIR

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

    2. A01CDJZ

      Install the clamp with the screw.

    3. A01CCZE

      Engage the 3 claws to install the heater clamp.

  5. INSTALL FRONT NO. 2 AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A01CD1EE01

      Using the reference point, install the front No. 2 air mix control servo motor sub-assembly with the 2 screws.

    2. Connect the connector.

  6. INSTALL FRONT NO. 1 AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A01CG4D

      Check that the slots, links and gears of the front No. 1 air mix control servo motor sub-assembly are positioned in the correct orientation as shown in the illustration.

    2. Face the contact surfaces of the front No. 1 air mix control servo motor sub-assembly and air conditioning radiator assembly for the front No. 1 air mix control servo motor sub-assembly upward.

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

      A01CF5E

    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.

      A01CEJ2E01

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

      A01CEEL

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

      A01CFL2E01
    7. A01CF6HE01

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

    8. Install the link of the front No. 1 air mix control servo motor sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

      A01CD6JE04

    9. Install the guide hole of the front No. 1 air mix control servo motor 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 front No. 1 air mix control servo motor sub-assembly slot.

      • Avoid tilting the front No. 1 air mix control servo motor sub-assembly during installation. This helps to prevent the guide pins from coming out of position.

    11. A01CC5I

      Lift the front No. 1 air mix control servo motor sub-assembly slightly to create clearance.

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

      A01CAXIE08
    13. A01CCO3

      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.

      A01CFGXE03
    15. A01CE9Z

      Push the loose fitting front No. 1 air mix control servo motor sub-assembly into position.

      Note


      • Make sure that the front No. 1 air mix control servo motor sub-assembly is fully pushed into position.

      • After pushing the servo into position, keep it in place by holding it until the screws are installed.

      Tech Tips

      Push the front No. 1 air mix control servo motor sub-assembly until a click sound is heard.

    16. Remove the screwdriver.

    17. A01CDBZ

      Fully install the top screw, and then install the front No. 1 air mix control servo motor sub-assembly with the 2 remaining screws.

    18. Remove the vinyl tape.

    19. A01CFJQ

      Connect the 2 connectors.

  7. INSTALL BLOWER ASSEMBLY


    1. A01CELX

      Engage the 2 claws.

    2. Install the blower assembly with the 2 screws.

    3. A01CDHO

      Engage each clamp.

    4. Connect the connector.

  8. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01CET5

      Engage the 3 claws to install the No. 3 air duct sub-assembly as shown in the illustration.

  9. INSTALL ASPIRATOR PIPE


    1. A01CAOX

      Engage the 2 claws and 2 clamps to install the aspirator pipe.

  10. INSTALL QUICK HEATER ASSEMBLY (for Cold Area)


    1. A01CD71

      Engage the 2 claws to install the 2 quick heater connectors.

    2. A01CD4T

      Install the quick heater assembly with the 2 screws as shown in the illustration.

    3. Install the 2 quick heater connectors and the bracket with the 2 screws.

    4. Engage each clamp.

  11. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY


    1. A01CCHJ

      Engage the 2 claws to install the No. 4 air duct sub-assembly.

  12. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. A01CBMC

      Engage the 4 claws to install the defroster nozzle assembly as shown in the illustration.

  13. INSTALL NO. 5 AIR DUCT SUB-ASSEMBLY


    1. A01CEIW

      Engage the 3 claws to install the No. 5 air duct sub-assembly as shown in the illustration.