Reassembly

HEATING / AIR CONDITIONING: FRONT AIR CONDITIONING UNIT: REASSEMBLY

REASSEMBLY

1. INSTALL FRONT EVAPORATOR TEMPERATURE SENSOR
NOTE: If reusing the evaporator, do not insert the sensor into a location where the sensor was previously inserted.

(a) Insert the sensor to a location that is 1 fin to the right or left of its previous location.
Standard:

2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Install the evaporator.
(b) Attach the 6 claws to install the unit case.
(c) Install the 7 screws.

3. INSTALL SERVO MOTOR

(a) Install the rear air mix damper control servo motor RH.
(1) Attach the claw to install the lever and servo motor.
(2) Install the 2 screws.

(b) Install the rear mode control servo motor.
(1) Attach the claw to install the plate and servo motor.
(2) Install the 2 screws.
(c) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the servo motor unit.

(d) Install the 3 screws.
4. INSTALL SERVO MOTOR

(a) Install the front air mix damper control servo motor LH.
(1) Attach the claw to install the plate and servo motor.
(2) Install the 2 screws.

(b) Install the front mode control servo motor LH.
(1) Attach the claw to install the plate and servo motor.
(2) Install the 2 screws.

(c) Attach the 3 claws to install the plate.
(d) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the servo motor unit.

(e) Install the 4 screws.
5. INSTALL SERVO MOTOR

(a) Install the front air mix damper control servo motor RH.
(1) Attach the claw to install the plate and servo motor.
(2) Install the 2 screws.

(b) Install the control air bypass damper control servo motor.
(1) Attach the claw to install the plate and servo motor.
(2) Install the 2 screws.

(c) Install the front mode control servo motor RH.
(1) Attach the claw to install the plate and servo motor.
(2) Install the 2 screws.
(d) Set the damper servo so that the cutout part engages with the tooth of the gear, and attach the claw to install the servo motor unit.

(e) Install the 4 screws.

6. INSTALL REAR AIR MIX DAMPER CONTROL SERVO MOTOR RH
(a) Install the servo motor with the 3 screws.
7. INSTALL COOLER EXPANSION VALVE (w/o Cool Box)

(a) Sufficiently apply compressor oil to 4 new O-rings and the fitting surface of the hose joint.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the 2 O-rings to the cooler evaporator.
(c) Install the 2 O-rings to the air conditioner tube and accessory assembly.
(d) Install the cooler expansion valve and air conditioner tube and accessory assembly to the evaporator.
(e) Using a 4 mm hexagon wrench, install the 2 bolts.
Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)

(f) Install new packing.

8. INSTALL AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Cool Box)
(a) Sufficiently apply compressor oil to 4 new O-rings and the fitting surface of the hose joint.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the 2 O-rings to the air conditioner tube and accessory assembly.
(c) Install the air conditioner tube and accessory assembly to the evaporator.
(d) Using a 4 mm hexagon wrench, install the 2 hexagon bolts.
Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
(e) Install the bracket with the screw.
9. INSTALL COOLER EXPANSION VALVE (w/ Cool Box)

(a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the hose joint.
Compressor oil:
ND-OIL 8 or equivalent
(b) Install the 2 O-rings to the No. 2 connector tube.
(c) Install the No. 2 connector tube, expansion valve and No. 3 connector tube.
(d) Using a 4 mm hexagon wrench, install the 2 hexagon bolts.
Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)

(e) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the hose joint.
Compressor oil:
ND-OIL 8 or equivalent
(f) Install the 2 O-rings to the No. 1 connector tube.
(g) Install the No. 1 connector tube.
(h) Using a 4 mm hexagon wrench, install the 2 hexagon bolts.
Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)

(i) Using a 4 mm hexagon wrench, install the bracket with the hexagon bolt and screw.

(j) Install new butyl tape.

(k) Install new packing.

10. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY
(a) Install the radiator.
(b) Install the bracket with the screw.
11. INSTALL AIR CONDITIONER HARNESS
(a) Attach the clamps to install the harness.
(b) Connect the connectors.

12. INSTALL QUICK HEATER ASSEMBLY (w/ PTC Heater)
(a) Install the quick heater with the 2 screws.
(b) Attach the 3 clamps.
13. INSTALL COOL BOX LIQUID TUBE (w/ Cool Box)

(a) Lubricate 2 new O-rings with compressor oil and install them to the liquid tube.
Compressor oil:
ND-OIL 8 or equivalent
(b) Connect the liquid tube with the piping clamp.
NOTE: After connection, check the claw engagement of the piping clamp.

14. INSTALL ASPIRATOR
(a) Attach the 2 claws to install the aspirator.

15. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY
(a) Install the duct with the screw.

16. INSTALL NO. 5 AIR DUCT SUB-ASSEMBLY
(a) Install the duct with the screw.
17. INSTALL BLOWER ASSEMBLY Installation