Air Conditioning Unit
DISASSEMBLY1. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
a. Release the 2 claws and remove the No. 2 air duct sub-assembly as shown in the illustration.
2. REMOVE BLOWER ASSEMBLY
a. Disconnect the connector.
b. Remove the 2 screws and blower assembly.
3. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY
a. Release the 4 claws and remove the No. 6 heater to register duct assembly.
4. REMOVE DRAIN COOLER HOSE
a. Remove the drain cooler hose from the air conditioning radiator assembly.
5. REMOVE QUICK HEATER ASSEMBLY
a. Remove the 3 screws and quick heater assembly.
6. REMOVE AIR OUTLET CONTROL SERVO MOTOR
a. Disconnect the 2 connectors and remove the air conditioner harness.
b. Remove the 3 screws and then remove the air outlet control servo motor.
7. REMOVE AIR MIX CONTROL SERVO MOTOR
a. Remove the 2 screws and air mix control servo motor.
8. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the screw and clamp.
b. Release the 4 claws and remove the clamp.
c. Remove the heater radiator unit sub-assembly from the air conditioning radiator assembly.
NOTE: Prepare a drain pan or cloth in case the coolant water leaks.
9. REMOVE COOLER EXPANSION VALVE
a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve.
10. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
a. Remove the 6 screws, release the 4 claws, and remove the plate cover.
b. Remove the clamp and No. 1 cooler thermistor.
c. Remove the No. 1 cooler evaporator sub-assembly.
d. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.
REASSEMBLY
1. INSTALL NO. 1 COOLER THERMISTOR
a. If using a new evaporator:
1. Install the No. 1 cooler thermistor to the evaporator as shown in the illustration.
b. If reusing the evaporator:
1. Install the No. 1 cooler thermistor to the evaporator as shown in the illustration.
2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
Compressor oil: ND-OIL 11 or equivalent
b. Install the No. 1 cooler evaporator sub-assembly.
c. Engage the 4 claws and install the plate cover with the 6 screws.
3. INSTALL COOLER EXPANSION VALVE
a. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.
Torque: 3.5 N.m (35 kgf.cm, 30 in.lbf)
4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Install the heater radiator unit sub-assembly to the air conditioning radiator assembly.
b. Install the clamp with the screw.
c. Engage the 4 claws and install the heater clamp.
5. INSTALL AIR MIX DAMPER CONTROL MOTOR
a. Install the air mix damper control motor with the 2 screws.
6. INSTALL AIR OUTLET CONTROL SERVO MOTOR
a. Install the air outlet control servo motor with the 3 screws.
b. Connect the 2 connectors and install the air conditioner harness.
7. INSTALL QUICK HEATER ASSEMBLY
a. Install the quick heater assembly with the 3 screws.
8. INSTALL DRAIN COOLER HOSE
a. Install the drain cooler hose to the air conditioning radiator assembly.
9. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY
a. Engage the 4 claws to install the No. 6 heater to register duct assembly.
10. INSTALL BLOWER ASSEMBLY
a. Install the blower assembly with the 2 screws.
b. Connect the connector.
11. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
a. Engage the 2 claws to install the No. 2 air duct sub-assembly.