AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER THERMISTOR


    1. A003UINE08
      Text in Illustration
      *1 From Tank
      *2 Fixed Part
      *3 Sensor Part

      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 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. 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.

      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. Install the No. 1 cooler evaporator sub-assembly together with the No. 1 cooler thermistor as a set.

    3. Engage the clamp.

    4. A003RPE

      Engage the 4 claws as shown in the illustration.

    5. Install the lower heater case with the 4 screws.

  3. INSTALL COOLER EXPANSION VALVE


    1. A003ULA

      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. Install the heater radiator unit sub-assembly to the air conditioning unit assembly.

    2. Install the clamp with the screw.

  5. INSTALL DRAIN COOLER HOSE


    1. A003SYT

      Install the drain cooler hose to the air conditioning unit assembly.

  6. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY


    1. Engage the 2 claws and install the air conditioning duct sub-assembly.

  7. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A003T0S

      Engage the claw.

    2. Install the air conditioning amplifier assembly with the screw.

  8. INSTALL NO. 1 FINISH PANEL MOUNTING BRACKET


    1. Install the No. 1 finish panel mounting bracket with the screw.

  9. INSTALL NO. 2 FINISH PANEL MOUNTING BRACKET


    1. Engage the 2 claws and install the No. 2 finish panel mounting bracket.

  10. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Connect the connector.

    2. Engage each clamp and install the air conditioning harness assembly.

  11. INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)


    1. A003U2P

      Install the quick heater assembly as shown in the illustration.

    2. Install the 2 screws.

    3. Engage each clamp.

  12. INSTALL AIR MIX CONTROL SERVO MOTOR


    1. A003UZVE02
      Text in Illustration
      *1 Reference Point

      Using the reference point, install the air mix control servo motor with the 3 screws.

    2. Connect the connector.

  13. INSTALL AIR OUTLET CONTROL SERVO MOTOR


    1. A003SSQE03
      Text in Illustration
      *1 Reference Point

      Using the reference point, install the air mix control servo motor with the 3 screws.

    2. Connect the connector.

  14. INSTALL BLOWER ASSEMBLY (w/o PTC Heater)


    1. Install the blower assembly with the 3 screws.

    2. Connect the connector.

  15. INSTALL BLOWER ASSEMBLY (w/ PTC Heater)


    1. Install the blower assembly with the 3 screws.

    2. Connect the connector.

    3. Engage the quick heater connector and install the screw.

    4. Engage each clamp.

  16. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. Engage the 2 claws and install the No. 3 air duct sub-assembly.

  17. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. Engage the 2 claws and install the No. 2 air duct sub-assembly.