Air Conditioning Unit

DISASSEMBLY

1. REMOVE HEATER TO REGISTER DUCT CENTER




a. Release the 4 claws and remove the heater to register duct center.

2. REMOVE AIR OUTLET CONTROL SERVO MOTOR




a. Remove the 3 screws and air outlet control servomotor.

3. REMOVE AIR MIX CONTROL SERVO MOTOR




a. LH side:
Remove the 3 screws and air mix control servomotor.




b. RH side:
Remove the 3 screws and air mix control servomotor.

4. REMOVE EVAPORATOR TEMPERATURE SENSOR




a. Release the clamp and connector.
b. Release the 2 claws and remove evaporator temperature sensor.

5. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY




a. Remove the 2 screws and piping cover.




b. Remove the screw and bracket.




c. Remove the heater radiator unit sub-assembly.

NOTE: Prepare a drain pan or cloth for cooling water leaks.

6. REMOVE AIR CONDITIONING TUBE ASSEMBLY




a. Remove the packing.




b. Using a hexagon wrench 4.0 mm, remove the 2 hexagon bolts and air conditioning tube assembly.
c. Remove the 2 O-rings from the air conditioning tube assembly.

7. REMOVE COOLER EXPANSION VALVE




a. Remove the cooler expansion valve from the cooler evaporator sub-assembly No.1.

8. REMOVE COOLER EVAPORATOR NO.1 SUB-ASSEMBLY




a. Remove the 3 screws and air duct sub-assembly.




b. Release the 4 claws and remove the air duct sub-assembly.




c. Remove the 11 screws and separate the heater case.
d. Remove the cooler evaporator No.1 sub-assembly.




e. Remove the 2 O-rings from the cooler evaporator No.1 sub-assembly.

REASSEMBLY

1. INSTALL COOLER EVAPORATOR NO.1 SUB-ASSEMBLY




a. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the cooler expansion valve.

Compressor oil:
ND-OIL 11 or equivalent

NOTE:
- 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 leakage of electric power.

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




c. Install the cooler evaporator No.1 sub-assembly to the heater case.
d. Install the heater case with the 11 screws.




e. Install the air duct sub-assembly with the 4 claws.




f. Install the air duct sub-assembly with the 3 screws.

2. INSTALL COOLER EXPANSION VALVE




a. Install the cooler expansion valve to the cooler evaporator No.1 sub-assembly.

3. INSTALL AIR CONDITIONING TUBE ASSEMBLY




a. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the air conditioning tube assembly. Compressor oil:

ND-OIL11 or equivalent

NOTE:
- 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 leakage of electric power.

b. Install the 2 O-rings on the air conditioning tube assembly.
c. Using a hexagon wrench 4.0 mm, install the air conditioning tube assembly with the 2 hexagon bolts.

Torque: 3.5 N.m (35 kgf.cm, 30 in.lbf)




d. Install a new packing.

NOTE:
- Be sure to install the packing securely so that there is no clearance.
- Wrap the packing with a shop rag or a piece of cloth as shown in the illustration to prevent moisture from entering.

4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY




a. Install the heater radiator unit sub-assembly.




b. Install the bracket with the screw.




c. Install the piping cover with the 2 screws.

5. INSTALL EVAPORATOR TEMPERATURE SENSOR




a. Engage the 2 claws to install the evaporator temperature sensor.
b. Engage the clamp to install the connector.

6. INSTALL AIR MIX CONTROL SERVO MOTOR




a. LH side:
Install the air mix control servomotor with the 3 screws.




b. RH side:
Install the air mix control servomotor with the 3 screws.

7. INSTALL AIR OUTLET CONTROL SERVO MOTOR




a. Install the air outlet control servomotor with the 3 screws.

8. INSTALL HEATER TO REGISTER DUCT CENTER




a. Engage the 4 clamps to install the heater to register duct center.