AIR CONDITIONING UNIT REASSEMBLY


  1. INSTALL NO. 1 AIR MIX DAMPER SERVO SUB-ASSEMBLY


    1. A019OMY

      Check that the slots, links and gears of the No. 1 air mix 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 mix damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air mix 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.

      A019MO9

    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.

      A019NYGE03
      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.

      A019LCY

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

      A019MC6E03
      Text in Illustration
      *a In-line Position - -
    7. A019KFCE02
      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 mix damper servo sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

      A019LJME05
      Text in Illustration
      *1 Guide *2 No. 1 Air Mix Damper Servo Sub-assembly
      *a No. 1 Air Mix 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 mix 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 mix damper servo sub-assembly slot.

      • Avoid tilting the No. 1 air mix damper servo sub-assembly during installation. This helps to prevent the guide pins from coming out of position.

    11. A019LA3

      Lift the No. 1 air mix 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 mix damper servo sub-assembly and air conditioning radiator assembly are aligned.

      A019K4GE05
      Text in Illustration
      *a No. 1 Air Mix Damper Servo Sub-assembly Alignment Hole *b Air Conditioning Radiator Assembly Alignment Hole
      *c Air Conditioning Radiator Assembly Gear Alignment Hole - -
    13. A019K5S

      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.

      A019K4VE05
      Text in Illustration
      *a Screwdriver is inserted into alignment holes. *b Link guide pin is inserted.
      *c Links is positioned to left side. *d Links is positioned at bottom.
      *e Each link guide pin is inserted in its No. 1 air mix damper servo sub-assembly slot. *f Lever is positioned at top.
      *g Links are in-line. - -
    15. A019NQD

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

      Note


      • Make sure that the No. 1 air mix damper servo sub-assembly is fully pushed into position.

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

      Tech Tips

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

    16. Remove the screwdriver.

    17. A019OXV

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

    18. Remove the vinyl tape.

  2. INSTALL NO. 1 COOLER THERMISTOR


    1. A019MDYE03
      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 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".

  3. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY


    1. A019LDQE01
      Text in Illustration
      *1 Front of Vehicle
      *2 Packing

      Engage the 4 claws to install the evaporator insulator as shown in the illustration.

      Note

      Install the evaporator insulator to the cooler evaporator sub-assembly after making sure that the packing is facing the front of the vehicle as shown in the illustration.

    2. A019OEH

      Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the cooler evaporator sub-assembly.

      Note

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

    4. A019NJC

      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.

    5. A019OIB

      Engage the 5 claws.

    6. Install the plate cover with the 6 screws.

  4. INSTALL ASPIRATOR PIPE


    1. A019OUO

      Engage the 2 claws and clamp to install the aspirator pipe.

  5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A019JT8

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

    2. A019JZIE01

      Install the clamp with the screw.

    3. Engage the 3 claws to install the heater clamp.

      Text in Illustration
      *1 Heater clamp
      *2 Clamp

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


    1. A019KF4E01
      Text in Illustration
      *1 Reference Point

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

  7. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY


    1. A019OVO

      Engage the 2 claws.

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

  8. INSTALL COOLER EXPANSION VALVE


    1. A019KHW

      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 }

  9. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Connect each connector.

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

      A019NJQ

  10. INSTALL NO. 5 AIR DUCT SUB-ASSEMBLY


    1. A019KFX

      Engage the guide and 2 claws to install the No. 5 air duct sub-assembly as shown in the illustration.

  11. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A019MR4

      Engage the guide and 2 claws to install the No. 3 air duct sub-assembly as shown in the illustration.