AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER THERMISTOR


    1. A003Z1RE01
      Text in Illustration
      *a From Tank
      *b Fixed Part
      *c 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 1.97 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 COOLER EVAPORATOR SUB-ASSEMBLY


    1. A003WXT

      Apply a sufficient amount of compressor oil to 2 new O-rings and the fitting surfaces.

      Compressor oil
      ND-OIL 11 or equivalent

    2. Install the 2 O-rings to the cooler evaporator subassembly.

      Note


      • Keep the O-rings and O-ring fitting surfaces free from dirt or any foreign matter.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    3. A003ZSL

      Engage the clamp and install the cooler evaporator sub-assembly with the No. 1 cooler thermistor.

      Tech Tips

      Completely cover the tube with the grommet.

    4. A003W4Q

      Engage the 4 claws.

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

    6. A003YBN

      Install the packing.

  3. INSTALL COOLER EXPANSION VALVE


    1. A003V75

      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 DRAIN COOLER HOSE


    1. A003YC1

      Install the drain cooler hose as shown in the illustration.

  5. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A003ZU8

      Engage the 2 guides to install the air conditioning amplifier assembly as shown in the illustration.

    2. Install the screw.

  6. INSTALL CONSOLE MOUNTING BRACKET RH


    1. A003Y3V

      Engage the 2 claws and install the console mounting bracket RH.

  7. INSTALL CONSOLE MOUNTING BRACKET LH


    1. A003ZF6

      Install the console mounting bracket LH with the screw.

  8. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A003XVK

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

    2. A003XK1E01
      Text in Illustration
      *1 Clamp

      Install the clamp with the screw.

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


    1. for LHD:


      1. A003VGE

        Install the quick heater assembly as shown in the illustration.

      2. A003YQD

        Install the 2 screws.

      3. Engage the 3 clamps.

    2. for RHD:


      1. A003VIE

        Install the quick heater assembly as shown in the illustration.

      2. A003YBK

        Install the 2 screws.

      3. Engage the 3 clamps.

  10. INSTALL AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A003VOME02
      Text in Illustration
      *a Reference Point

      Using the reference point, install the air outlet control servo motor sub-assembly with the 3 screws.

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


    1. A003VOJE02
      Text in Illustration
      *a Reference Point

      Using the reference point, install the No. 2 air mix control servo motor sub-assembly with the 3 screws.

  12. INSTALL AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY


    1. A003V2RE02
      Text in Illustration
      *a Reference Point

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

  13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Connect each connector.

      A003W76

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

  14. INSTALL ASPIRATOR (for LHD)


    1. A003ZDW

      Engage the 2 claws and install the aspirator.

  15. INSTALL ASPIRATOR (for RHD)


    1. A003WPS

      Engage the 2 claws and install the aspirator.

  16. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for LHD)


    1. A003YX7

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

  17. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A003V9T

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

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


    1. Engage the guide.

    2. Install the blower assembly with the 3 screws.

    3. Connect the connector.

  19. INSTALL BLOWER ASSEMBLY (w/ PTC Heater)


    1. Engage the guide.

    2. Install the blower assembly with the 3 screws.

    3. Connect the connector.

    4. Engage each clamp.

    5. Install the screw and connect the quick heater connector.

    6. Reattach the felt tape.