FRONT AIR CONDITIONING UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. INSTALL NO. 1 COOLER THERMISTOR (w/ Cooler System)

    Click here

  2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (w/ Cooler System)


    1. A01WA4N

      Install the No. 1 cooler evaporator sub-assembly together with the No. 1 cooler thermistor to the upper heater case.

    2. Connect the connector clamp to the upper heater case.

    3. Attach the claw to install the upper heater case to the lower heater case.

      A01WBAF

    4. Install the 2 screws.

  3. INSTALL COOLER EXPANSION VALVE


    1. A01WAQE

      Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the No. 1 cooler evaporator sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    3. Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 bolts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for Automatic Air Conditioning System, Manual Air Conditioning System)


    1. A01W9S5C01
      B0069FO Install in this Direction

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

    2. A01WBL7

      Install the heater radiator cover with the 2 screws.

    3. A01WBAH

      Attach the claw to install the heater clamp.

    4. A01WBT4

      Install the packing.

  5. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System, w/ Rear Duct)


    1. Attach the arm of the No. 2 air conditioning radiator damper servo sub-assembly to the link of the air conditioner radiator assembly as shown in the illustration.

      A01WA2UC01
      *a Align as shown - -
    2. A01W99N

      Install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

  6. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. Align each gear on the air conditioning radiator assembly side as shown in the illustration, and then check that the gears of the No. 1 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.

      A01W8ZUC01
      *a Align as shown - -
    2. A01WBGD

      Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.

  7. INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System, Manual Cooler System)


    1. A01W9YM

      Attach the arm of the defroster damper control cable sub-assembly to the link of the blower assembly as shown in the illustration.

    2. Attach the claw to install the defroster damper control cable sub-assembly.

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


    1. A01WALD

      Attach the arm of the air mix damper control cable sub-assembly to the link of the blower assembly as shown in the illustration.

    2. Attach the claw to install the air mix damper control cable sub-assembly.

  9. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A01W879

      Install the air conditioning amplifier bracket with the 3 screws.

    2. A01WB7YC01
      B0069FO Install in this Direction

      for Automatic Air Conditioning System:

      Install the air conditioning amplifier assembly with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    3. A01WAWRC02
      B0069FO Install in this Direction

      for Manual Air Conditioning System, for Manual Cooler System:

      Install the air conditioning amplifier assembly with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

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


    1. w/o Rear Duct:


      1. Attach the clamp to install the air conditioning harness assembly.

      2. Connect the 3 connectors.

        A01WBPG

    2. w/ Rear Duct:


      1. Attach the clamp to install the air conditioning harness assembly.

      2. Connect the 4 connectors.

        A01W8E8

  11. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A01W838

      Attach the claw and clamp to install the air conditioning duct sub-assembly.

  12. INSTALL BLOWER ASSEMBLY

    Click here

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


    1. A01WAV8C01
      B0069FO Install in this Direction

      Install the heater cover with the screw.

  14. INSTALL HEATER COVER (w/o PTC Heater)


    1. A01WAV8C01
      B0069FO Install in this Direction

      Install the heater cover with the screw.