Disassembly and Reassembly

COOLING UNIT

DISASSEMBLY

1. REMOVE THERMISTOR




a. Disconnect the connector clamp.
b. Using a screwdriver, pull out the thermistor.

HINT: Tape the screwdriver tip before use.




c. Release the 2 claw and remove the thermistor from the bracket plate.

2. REMOVE BLOWER RESISTOR
Remove the 2 screws and blower resistor.




3. SEPARATE UPPER AND LOWER UNIT CASE
a. Using a knife, cut off each packing.
b. Remove the 6 screws holding the upper to the lower unit case.
c. Separate the upper and lower unit case.

4. REMOVE EVAPORATOR
Remove the evaporator from the lower unit case.




5. REMOVE EXPANSION VALVE
Using a 5 mm hexagon wrench, remove the 2 bolts, and separate the expansion valve and evaporator.

REASSEMBLY




1. INSTALL EXPANSION VALVE
a. Coat 4 new O-rings with compressor oil.
b. Using a 5 mm hexagon wrench, install the expansion valve to the evaporator with the 2 bolts.

Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)

2. INSTALL EVAPORATOR
Install the evaporator to the lower case unit.
If evaporator was replaced, add compressor oil to the compressor.

Add 40 cc (1.4 fl.oz.)
Compressor oil: ND-OIL 8 or equivalent




3. ASSEMBLE UPPER AND LOWER UNIT CASES
a. Assemble the upper and lower unit cases.
b. Install the 6 screws.

4. INSTALL BLOWER RESISTER
Install the blower resister with the 2 screws.




5. INSTALL THERMISTOR
a. Install the thermistor to the bracket plate.
b. Push into the thermistor to the cooling unit.
c. Connect the connector clamp.