AIR CONDITIONING UNIT REASSEMBLY

PROCEDURE

INSTALL HEATER CASE SUB-ASSEMBLY
1. Engage the 10 claws to install a new heater case sub-assembly.
INSTALL NO. 1 COOLER THERMISTOR

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INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
1. 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 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 of foreign matter.
3. Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the air duct as shown in the illustration.
4. Engage the clamp.
5. Engage the 5 claws to install the air duct with No. 1 cooler evaporator sub-assembly to the heater case.
6. Install the 5 screws.
INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. Install the No. 3 air conditioning radiator damper servo sub-assembly with the 3 screws.
  
  Note
  
  Make sure that each link guide pin of the No. 3 air conditioning radiator damper servo sub-assembly are inserted in each guide hole of the air conditioning radiator assembly.
2. Engage the claw.
INSTALL NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. *a Reference Point
  
  Using the reference points, install the No. 5 air conditioning radiator damper servo sub-assembly with the 2 screws.
INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LH Side)
1. *a Reference Point
  
  Using the reference point, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

Compressor Oil
ND-OIL 8 or equivalent

INSTALL NO. 4 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

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

*1	No. 4 Air Conditioning Radiator Damper Servo Sub-assembly	*2	Air Conditioning Radiator Assembly
*a	Reference Point	-	-

INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RH Side)
1. *a Reference Point
  
  Using the reference point, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

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

*1	No. 1 Air Conditioning Radiator Damper Servo Sub-assembly
*2	Air Conditioning Radiator Assembly
*a	Reference Point

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

INSTALL HEATER GROMMET
1. Install the heater grommet.
INSTALL NO. 2 COOLING UNIT PACKING
1. Remove any remaining No. 2 cooling unit packing from the air conditioner radiator assembly.
2. Remove the release paper from a new No. 2 cooling unit packing.
3. Install the No. 2 cooling unit packing as shown in the illustration.
  
  Dimension Measurement
  
  A -3.0 to 3.0 mm (0.118 to 0.118 in.)
INSTALL HEATER COVER (w/o PTC Heater)
1. Engage the 2 claws to install the heater cover as shown in the illustration.
2. w/ Screw:
  1. Install the screw.
INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)
1. Engage the 2 claws to install the quick heater assembly as shown in the illustration.
2. w/ Screw:
  1. Install the screw.
INSTALL HEATER PIPING COVER (for RHD)
1. Install the heater piping cover to the heater radiator unit sub-assembly.
INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
1. for LHD:
  1. Install the heater radiator unit sub-assembly as shown in the illustration.
2. for RHD:
  1. Install the heater radiator unit sub-assembly as shown in the illustration.
  2. Install the screw.
3. Engage the 3 claws to install the heater clamp.
INSTALL HEATER PACKING
1. Install the heater packing.
INSTALL COOLER EXPANSION VALVE
1. Install the cooler expansion valve.
INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
1. Remove the vinyl tape from the air conditioner tube and accessory assembly.
2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the air conditioner tube and accessory assembly.
  
  Compressor Oil
  
  ND-OIL 8 or equivalent
3. Install the 2 O-rings to the air conditioner tube and accessory assembly.
  
  Note
  
  Keep the O-rings and O-ring fitting surfaces free of foreign matter.
4. Using a 4 mm hexagon socket wrench, install the air conditioner tube and accessory assembly with the 2 hexagon bolts.
  
  Torque:
  
  3.5 N*m { 36 kgf*cm, 31 in.*lbf }
INSTALL NO. 1 COOLING UNIT PACKING
1. Remove any remaining No. 1 cooling unit packing from the air conditioner tube and accessory assembly and cooler expansion valve.
2. Remove the release paper from a new No. 1 cooling unit packing.
3. Install the No. 1 cooling unit packing as shown in the illustration.
INSTALL NO. 3 COOLING UNIT PACKING
1. Remove any remaining No. 3 cooling unit packing from the air conditioner tube and accessory assembly.
2. Remove the release paper from a new No. 3 cooling unit packing.
3. Install the No. 3 cooling unit packing.
INSTALL COOLER PLATE
1. Install the cooler plate.
INSTALL NO. 4 COOLING UNIT PACKING
1. Remove any remaining No. 4 cooling unit packing from the cooler plate.
2. Remove the release paper from a new No. 4 cooling unit packing.
3. Install the No. 4 cooling unit packing.
INSTALL AIR CONDITIONING HARNESS ASSEMBLY
1. Engage the clamp.
2. Connect each connector to install the air conditioning harness assembly.
INSTALL ASPIRATOR PIPE
1. Engage the 2 claws to install the aspirator pipe.
INSTALL AIR HOSE
1. Install the air hose.
INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
1. Engage the 3 claws to install the lower defroster nozzle assembly.
INSTALL BLOWER ASSEMBLY

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