Reassembly

AIR CONDITIONING: AIR CONDITIONING UNIT: 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.





(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 Nm (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) Set the air mix control servo motor to the standard position shown in the illustration, and then install it with the 2 screws.





(b) Connect the connector.

6. INSTALL AIR OUTLET CONTROL SERVO MOTOR

(a) Check that the slots, links and gears of the air outlet control servo motor are positioned in the correct orientation as shown in the illustration.





(b) Face the contact surfaces of the air outlet control servo motor and air conditioning unit assembly for the air outlet control servo motor upward.

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





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





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





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





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





(h) Install the link of the air outlet control servo motor to the link guide pin (A) of the air conditioning unit assembly as shown in the illustration.





(i) Install the guide hole of the air outlet control servo motor to the guide pin of the air conditioning unit 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 air conditioning unit assembly slot.
* Avoid tilting the air conditioning unit assembly during installation. This helps to prevent the guide pins from coming out of position.

(k) Lift the air outlet control servo motor slightly to create clearance.





(l) Move the air conditioning unit assembly gear so that alignment holes of the air outlet control servo motor and air conditioning unit assembly are aligned.





(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.





(o) Push the loose fitting air outlet control servo motor into position.





NOTICE:
* Make sure that the air outlet control servo motor is fully pushed into position.
* After pushing the servo into position, keep it in place by holding it until the screws are installed.

HINT
Push the air outlet control servo motor until a click sound is heard.

(p) Remove the screwdriver.

(q) Fully install the top screw, and then install the air outlet control servo motor with the 2 remaining screws.





(r) Remove the vinyl tape.

(s) Connect the 2 connectors.





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.