Disassembly and Reassembly

DISASSEMBLY




1. REMOVE EXPANSION VALVE
a. Pry out the packing.
b. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and expansion valve.

NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system.




2. REMOVE AIR OUTLET SERVOMOTOR
a. Using a screwdriver, release the claw and remove the plate.

HINT: Tape the screwdriver tip before use.




b. Disconnect the connector.
c. Remove the 3 screws and servomotor.

3. REMOVE AIR DUCT (for Foot)




4. Auto A/C only:
REMOVE AIR MIX SERVOMOTOR

Remove the 3 screws and servomotor.




5. REMOVE HEATER RADIATOR
a. Release the 3 claws and pull out the heater protector.
b. Remove the 3 screws and 3 plates.
c. Remove the 2 clips and remove the 2 heater radiator pipes.
d. Pull out the heater radiator.

6. Auto A/C only:
REMOVE BLOWER MOTOR LINEAR CONTROLLER
Remove the 2 screws and blower motor linear controller.




7. REMOVE EVAPORATOR
a. Remove the grommet from the evaporator.
b. Using a knife, cut off each packings.
c. Remove the 12 screws and separate the heater cases, then remove the evaporator.
d. Release the 4 claws and remove the plate.




8. REMOVE EVAPORATOR TEMPERATURE SENSOR
Remove the 2 holders and the sensor.

REASSEMBLY




1. INSTALL EVAPORATOR TEMPERATURE SENSOR
Install the sensor with the 2 holders.

2. INSTALL EVAPORATOR




a. Install the plate to evaporator.
b. Apply water seal to heater case as shown in the illustration.




c. Install the insulator to heater case.
d. Install the evaporator on the insulator

HINT: If evaporator is replaced, add compressor oil to evaporator.

Add 40 cc (1.4 fl.oz.)

Compressor oil: ND-OIL 8 or equivalent

e. Install the heater cases with the 13 screws.
f. Apply the new packings.
g. Install the grommet to evaporator.

3. INSTALL HEATER RADIATOR
a. Install 2 new O-rings to heater radiator pipes.
b. Install the heater radiator pipes.
c. Install the 2 clamps with the 2 screws.
d. Install the heater radiator to heater case.
e. Install the 2 plate with 2 screws.

4. Auto A/C only:
INSTALL BLOWER MOTOR LINEAR CONTROLLER
Install the blower motor linear controller with the 2 screws.




5. Auto A/C only:
INSTALL AIR MIX SERVOMOTOR

Install the servomotor with 3 screws.

6. INSTALL AIR OUTLET SERVOMOTOR




a. Install the servomotor with the 3 screws.




b. Insert the drain of the plate to the pin and fit the claw.

7. INSTALL EXPANSION VALVE
a. Lubricate 2 new O-rings with compressor oil and install them to the tube and accessory.

Compressor oil: ND-OIL 8 or equivalent

b. Install the tube and accessory to the expansion valve.




c. Apply the new packing.
1. Using a knife, cut off packing paper of packing while peel off the paper, as shown in the illustration.

HINT: Leave the packing paper untaped on the tube side so that the installation bolt hole for remains visible.




2. Apply the packing.






NOTE: Do not overtape the packing beyond the expansion valve edge.




d. Lubricate 2 new O-rings with compressor oil and install them to the expansion valve.

Compressor oil: ND-OIL 8 or equivalent

e. Using a hexagon wrench (5.0 mm, 0.20 in.), with the 2 bolts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

NOTE: When installing the expansion valve, take care so that the packing is not jammed with the evaporator.

f. Peel off remaining packing paper and apply the packing to expansion valve.