AIR CONDITIONING UNIT (for Automatic Air Conditioning System) REASSEMBLY

Tech Tips


  • Use the same procedure for LHD and RHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.


  1. INSTALL FRONT EVAPORATOR TEMPERATURE SENSOR

    A003CSWE04
    Text in Illustration
    *1 1 Fin
    *2 Sensor Part
    *3 Part Used to Hold Sensor in Place
    *4 from Tank
    *5 Front Evaporator Temperature Sensor

    Note

    If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted.


    1. Insert the sensor to a location that is 1 fin to the right or left of its previous location.

      Standard
      Area Specified Condition
      A 50 mm (1.97 in.)
      B 34.3 mm (1.35 in.)
      C 20.9 mm (1.97 in.)

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

    A003BIJ

    1. Install the evaporator.

    2. Attach the clamp.

    3. Attach the 4 claws to install the unit case.

    4. Install the 4 screws.

      A003BK7

  3. INSTALL COOLER EXPANSION VALVE

    A003EOA

    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the hose joint.

      Compressor oil
      ND-OIL 8 or equivalent

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

    3. Install the cooler expansion valve to the No. 1 cooler evaporator sub-assembly.

    4. Using a 4 mm hexagon wrench, install the 2 bolts.

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

  4. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Attach the clamps to install the harness.

    2. Connect the connector.

      A003CAU

  5. INSTALL DRAIN COOLER HOSE

    A003CYFE01
    Text in Illustration
    *1 Alignment Mark
    *2 Protrusion

    1. Install the drain cooler hose as shown in the illustration.

  6. INSTALL ASPIRATOR

    A003BKO

    1. Attach the 2 claws to install the aspirator.

  7. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY

    A003BXZ

    1. Install the radiator.

    2. Install the bracket with the screw.

  8. INSTALL PTC HEATER ASSEMBLY (w/ PTC Heater)


    1. A003BHC

      Install the PTC heater as shown in the illustration.

    2. A003EG0

      Install the 2 screws.

    3. Attach the clamp.

  9. INSTALL MODE DAMPER SERVO SUB-ASSEMBLY

    A003AMI

    1. Set the damper servo so that the tooth of the gear engages with the cutout part as shown in the illustration to install the damper servo.

    2. Install the 3 screws.

    3. Connect the connector.

  10. INSTALL AIR MIX DAMPER SERVO SUB-ASSEMBLY

    A003CBM

    1. Set the damper servo so that the tooth of the gear engages with the cutout part as shown in the illustration to install the damper servo.

    2. Install the 3 screws.

    3. Connect the connector.

  11. INSTALL NO. 2 AIR MIX DAMPER SERVO SUB-ASSEMBLY

    A003CUM

    1. Set the damper servo so that the tooth of the gear engages with the cutout part as shown in the illustration to install the damper servo.

    2. Install the 3 screws.

    3. Connect the connector.

  12. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    A003BNT

    1. Install the amplifier assembly with the screw.

    2. Connect the connector.

  13. INSTALL BLOWER ASSEMBLY

    A003BY7

    1. Install the blower assembly with the 3 screws.

    2. Connect the connector.

    3. A003AFU

      w/ PTC Heater:

      Install the screw.

    4. A003BU7

      w/ PTC Heater:

      Attach the 3 clamps.