Reassembly

HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY

1. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Check that the slots, links and gears of the No. 1 air conditioning radiator damper servo sub-assembly are positioned in the correct orientation as shown in the illustration.

(b) Face the contact surfaces of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air conditioning radiator damper servo sub-assembly upward.

(c) Rotate the link of the air conditioning radiator assembly all the way to the left as shown in the illustration.

(d) Rotate the link of the air conditioning radiator assembly to the bottom as shown in the illustration and confirm that the mode switching duct hole is fully closed.

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(e) Rotate the lever of the air conditioning radiator assembly to the top as shown in the illustration.

(f) Rotate the link of the air conditioning radiator assembly to the in-line position as shown in the illustration.

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(g) Wrap the upper and lower links with vinyl tape to hold them in the in-line position.

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(h) Install the link of the No. 1 air conditioning radiator damper servo sub-assembly to the link guide pin (A) of the air conditioning radiator assembly as shown in the illustration.

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(i) Install the guide hole of the No. 1 air conditioning radiator damper servo sub-assembly to the guide pin of the air conditioning radiator assembly as shown in the illustration.

(j) Temporarily install the screw (up to 4 or 5 threads).

NOTICE:
* Make sure that the link guide pin (B) is inserted in the No. 1 air conditioning radiator damper servo sub-assembly slot.
* Avoid tilting the air conditioning radiator assembly during installation. This helps to prevent the guide pins from coming out of position.

(k) Lift the No. 1 air conditioning radiator damper servo sub-assembly slightly to create clearance.

(l) Move the air conditioning radiator assembly gear so that alignment holes of the No. 1 air conditioning radiator damper servo sub-assembly and air conditioning radiator assembly are aligned.

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(m) Insert a screwdriver into the aligned holes as shown in the illustration.

(n) Make sure that all the links and gears are in the positions shown in the illustration.

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(o) Push the loose fitting No. 1 air conditioning radiator damper servo sub-assembly into position.

NOTICE:
* Make sure that the No. 1 air conditioning radiator damper servo sub-assembly are fully pushed into position.
* After pushing the servos into position, keep them in place by holding them until the screws are installed.

HINT
Push the No. 1 air conditioning radiator damper servo sub-assembly until a click sound is heard.

(p) Remove the screwdriver.

(q) Fully install the top screw, and then install the No. 1 air conditioning radiator damper servo sub-assembly with the 2 remaining screws.

(r) Remove the vinyl tape.

2. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Install the heater radiator unit sub-assembly to the air conditioner radiator assembly.

(b) Install the clamp with the screw.

3. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)

(a) Using the reference point, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

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4. INSTALL NO. 1 COOLER THERMISTOR Installation

5. 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 8 or equivalent

(b) Install the No. 1 cooler evaporator sub-assembly to the blower assembly.

6. INSTALL BLOWER ASSEMBLY WITH COOLER EVAPORATOR SUB-ASSEMBLY Installation

7. INSTALL COOLER EXPANSION VALVE

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

Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Manual Air Conditioning System)

(a) Engage the 5 clamps to install air conditioning harness assembly.

(b) Connect the 4 connectors.

(c) Install the heater packing as shown in the illustration.

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

(a) Engage the 5 clamps to install air conditioning harness assembly.

(b) Connect the 5 connectors.

(c) Install the heater packing as shown in the illustration.

10. INSTALL ASPIRATOR

(a) Engage the 2 claws to install the aspirator.

11. INSTALL COOLER THERMISTOR HOSE (for Automatic Air Conditioning System)

(a) Engage the clamp to install the cooler thermistor hose.

12. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY

(a) Engage the 2 claws and 2 guides to install the No. 6 heater to register duct assembly as shown in the illustration.

13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Engage the 2 claws and guide to install the No. 1 air duct sub-assembly as shown in the illustration.