AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 COOLER THERMISTOR


    1. A01EY8RE05
      Text in Illustration
      *a Fixed Part
      *b 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 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 NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. A01ESZL

      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

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

      Note

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

    3. A01EW65

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

      Tech Tips

      Completely cover the tube with the grommet.

    4. A01ETV7

      Engage the 5 claws.

    5. Install the plate cover with the 6 screws.

  3. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A01EVGT

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

    2. A01EVHR

      Install the clamp with the screw.

    3. A01EUS8

      Engage the 3 claws and install the heater clamp.

  4. INSTALL NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for 3 Zone Type)


    1. A01EWW1E01
      Text in Illustration
      *1 Reference Point

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

  5. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. A01EVP9E01
      Text in Illustration
      *1 Reference Point

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

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


    1. A01EXO9

      Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo sub-assembly are positioned in the correct orientation as shown in the illustration.

    2. Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air conditioning radiator damper servo sub-assembly upward.

    3. Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.

      A01EVI2

    4. Rotate the link of the air conditioning radiator assembly to the bottom as shown in the illustration and confirm that the mode switching duct hole is fully closed.

      A01EVKUE03
      Text in Illustration
      *a Mode Switching Duct Hole - -

    5. Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.

      A01EY2F

    6. Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

      A01ETXLE03
      Text in Illustration
      *a In-line Position - -
    7. A01EXTTE02
      Text in Illustration
      *1 Vinyl Tape

      Wrap the upper and lower links with vinyl tape to hold them in the in-line position.

    8. Install the link of the No. 1 air conditioning radiator damper servo sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

      A01ETULE05
      Text in Illustration
      *1 Guide *2 No. 1 Air Conditioning Radiator Damper Servo Sub-assembly
      *a No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Slot *b Link Guide Pin (A)
      *c Link Guide Pin (B) - -

    9. Install the guide hole of the No. 1 air conditioning radiator damper servo sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration.

    10. Temporarily install the screw (up to 4 or 5 threads).

      Note


      • Make sure that the link guide pin (B) is inserted in the No. 1 air conditioning radiator damper servo sub-assembly slot.

      • Avoid tilting the air conditioning radiator assembly during installation. This helps to prevent the guide pins from coming out of position.

    11. A01ET31

      Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

    12. Move the air conditioning radiator assembly gear so that alignment holes of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly are aligned.

      A01EUSJE05
      Text in Illustration
      *a No. 1 Air Conditioning Radiator Damper Servo Sub-assembly Alignment Hole *b Air Conditioning Radiator Assembly Alignment Hole
      *c Air Conditioning Radiator Assembly Alignment Gear Alignment Hole - -
    13. A01EXDR

      Insert a screwdriver into the aligned holes as shown in the illustration.

    14. Make sure that all the links and gears are in the positions shown in the illustration.

      A01EXRQE05
      Text in Illustration
      *a Screwdriver is inserted into alignment holes. *b Link guide pin is inserted.
      *c Link is positioned to left side. *d Link is positioned at bottom.
      *e Each link guide pin is inserted in its No. 1 air conditioning radiator damper servo sub-assembly slot. *f Lever is positioned at top.
      *g Links are in-line. - -
    15. A01EUF6

      Push the loose fitting No. 1 air conditioning radiator damper servo sub-assembly into position.

      Note


      • Make sure that the No. 1 air conditioning radiator damper servo sub-assembly are fully pushed into position.

      • After pushing the servos into position, keep them in place by holding them until the screws are installed.

      Tech Tips

      Push the No. 1 air conditioning radiator damper servo sub-assembly until a click sound is heard.

    16. Remove the screwdriver.

    17. A01EUHY

      Fully install the top screw, and then install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 remaining screws.

    18. Remove the vinyl tape.

  7. INSTALL DRAIN COOLER HOSE


    1. A01EXY8E01
      Text in Illustration
      *1 Hose Notch
      *2 Air Conditioning Radiator Assembly Rib

      Install the drain cooler hose to the air conditioning radiator assembly as shown in the illustration.

  8. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY


    1. A01EYJW

      Engage the 2 claws.

    2. Install the air conditioning radiator assembly with the 2 screws.

  9. INSTALL COOLER EXPANSION VALVE


    1. A01EUS7

      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 }

  10. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Dual Type)


    1. A01EY6K

      Engage the 7 clamps to install the air conditioning harness assembly.

    2. Connect the 5 connectors.

    3. A01EU7V

      Install the heater packing as shown in the illustration.

  11. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for 3 Zone Type)


    1. A01EU6F

      Engage the 7 clamps to install the air conditioning harness assembly.

    2. Connect the 6 connectors.

    3. A01EU7V

      Install the heater packing as shown in the illustration.

  12. INSTALL ASPIRATOR


    1. A01EYON

      Engage the 2 claws to install the aspirator.

  13. INSTALL COOLER THERMISTOR HOSE


    1. A01EU49

      Engage the clamp to install the cooler thermistor hose.

  14. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A01EVU7

      Engage the 2 claws and 2 guides to install the No. 6 heater to register duct assembly as shown in the illustration.

  15. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01EWIW

      Engage the guide and 2 claws to install the No. 1 air duct sub-assembly as shown in the illustration.