Air Conditioning Unit

DISASSEMBLY

1. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY




a. Release the 2 claws and remove the No. 2 air duct sub-assembly as given 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 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.

6. REMOVE AIR MIX CONTROL SERVO MOTOR




a. Remove the 2 screws and air mix control servo motor.

7. 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 cooling water leaks.

8. REMOVE COOLER EXPANSION VALVE




a. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve.

9. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY




a. Remove the 6 screws, release the 5 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 given in the illustration.




b. If reusing the evaporator:
1. Install the No. 1 cooler thermistor to the evaporator as given 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.
b. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.

Compressor oil: ND-OIL 8 or equivalent




c. Install the No. 1 cooler evaporator sub-assembly.




d. Engage the 5 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 conditioner radiator assembly.




b. Install the clamp with the screw.
c. Engage the 4 claws and install the heater clamp.

5. INSTALL AIR MIX CONTROL SERVO MOTOR




a. Install the air mix control servo 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 DRAIN COOLER HOSE




a. Install the drain cooler hose to the air conditioner radiator assembly.

8. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY




a. Engage the 4 claws to install the No. 6 heater to register duct assembly.

9. INSTALL BLOWER ASSEMBLY




a. Install the blower assembly with the 2 screws.
b. Connect the connector.

10. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY




a. Engage the 2 claws to install the No. 2 air duct sub-assembly.