AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER THERMISTOR

    A0118DUE01

    1. Install front evaporator temperature sensor as shown in the illustration.

      Standard
      Part Length
      *1 48 to 52 mm (1.890 to 2.047 in.)
      *2 20.9 mm (0.823 in.)
      *3 34.3 mm (1.350 in.)

      Note


      • Be sure to insert the sensor only once because reinserting it will not allow it to be firmly secured.

      • When reusing the evaporator, insert the sensor one row next to the one that was used previously (*4 in the illustration).

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

      • Directly insert the sensor until the edge of the plastic case "*5" comes into contact with the evaporator "*6".

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

    Tech Tips

    If a new cooler evaporator is installed, add compressor oil to the cooler evaporator as follows.

    Capacity
    Add 40 cc (1.35 fl. oz.)
    Compressor oil
    ND-OIL8 or equivalent.

    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings onto the cooler evaporator.

      Compressor oil
      ND-OIL 8 or equivalent

      Note

      Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.

    2. A0117FU

      Install the cooler evaporator together with the cooler thermistor as a set.

    3. A011B82

      Engage the 2 claws and install the heater case (pipe cover).

    4. A0118UE

      Engage the 10 claws and install the heater case (lower case).

    5. A0119I2

      Install the new protector.

  3. INSTALL CLEAN AIR FILTER

    A011BHO

    1. Install the clean air filter.

  4. INSTALL AIR FILTER CASE

    A0118ZH

    1. Engage the claw and install the air filter case.

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

    A011ACZ

    1. Engage the 4 claws and install the air conditioning harness.

  6. INSTALL MODE DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

    A0117OPE01
    Text in Illustration
    *1 Reference position

    1. Align the reference position and the claw, and then install the mode damper servo.

  7. INSTALL HEATER ACCESSORY ASSEMBLY

    A0118AJ

    1. Engage the 3 claws and install the heater accessory.

    2. Tighten the screw.

  8. INSTALL DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

    A01190UE01
    Text in Illustration
    *1 Reference position

    1. Align the reference position and the claw, and then install the damper servo.

  9. INSTALL AIR MIX DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

    A011A3ME01
    Text in Illustration
    *1 Reference position

    1. Align the reference position and the claw, and then install the air mix damper servo.

  10. INSTALL NO. 2 HEATER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)

    A011B3XE01
    Text in Illustration
    *1 FACE position

    1. Align the heater control cable gear and unit gear in the FACE position.

    2. Engage the claw and install the heater control cable.

  11. INSTALL AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)

    A0117U1E01
    Text in Illustration
    *1 Reference position

    1. Align the reference position and the claw, and then install the air inlet damper cable.

  12. INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)

    A01194Y

    1. Engage the claw, 2 guides and install the air mix damper control cable onto the air conditioner unit.

    2. Engage the claw and install the air mix damper control cable.

  13. INSTALL NO. 1 INSTRUMENT PANEL MOUNTING BRACKET

    A0117NN

    1. Install the instrument panel mounting bracket with the screw.

  14. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    A01188G

    1. Install the air conditioning amplifier with the clip.

  15. INSTALL COOLER EXPANSION VALVE

    A0118HD

    1. 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 }

  16. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

    A011AVO

    1. Install the heater radiator unit.

  17. INSTALL NO. 1 COOLER COVER

    A011A8S

    1. Engage the 2 claws and install the cooler cover.

  18. INSTALL QUICK HEATER ASSEMBLY (for Cold Area Specification Vehicles)

    A01173Q

    1. Install the quick heater with the 2 screws.

  19. INSTALL BLOWER W/FAN MOTOR SUB-ASSEMBLY

    A011BGU

    1. Install the blower w/fan motor with the 3 screws.

  20. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (except Cold Area Specification Vehicles)

    A0118S6

    1. Engage the 3 claws and install the air duct.

  21. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (except Cold Area Specification Vehicles)

    Tech Tips

    Use the same procedure as for the No. 2 side.

  22. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for Cold Area Specification Vehicles)

    A011AI0

    1. Engage the 3 claws and install the air duct.

  23. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for Cold Area Specification Vehicles)

    Tech Tips

    Use the same procedure as for the No. 2 side.