Reassembly

HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY

1. INSTALL NO. 1 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMC Made)

(a) Check that the slots, links and gears of the No. 1 air mix 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 mix damper servo sub-assembly and air conditioning radiator assembly for the No. 1 air mix 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.

Text in Illustration

(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 mix 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 mix 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 air conditioning unit 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 mix 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 mix damper servo sub-assembly and air conditioning radiator assembly are aligned.

Text in Illustration

(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 mix damper servo sub-assembly into position.

NOTICE:
* Make sure that the No. 1 air mix damper servo sub-assembly 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 No. 1 air mix 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 mix damper servo sub-assembly with the 2 remaining screws.

(r) Remove the vinyl tape.

2. INSTALL NO. 1 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMMC Made)

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

Text in Illustration

(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.

Text in Illustration

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

Text in Illustration

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

Text in Illustration

(i) Install the guide hole of the No. 1 air mix 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 air conditioning radiator 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 mix 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 mix damper servo sub-assembly and air conditioning radiator assembly are aligned.

Text in Illustration

(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.

Text in Illustration

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

(r) Remove the vinyl tape.

3. INSTALL NO. 1 COOLER THERMISTOR Installation

4. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY (for TMC Made)

(a) Engage the 4 claws to install the evaporator insulator as shown in the illustration.

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NOTICE:
Install the evaporator insulator to the cooler evaporator sub-assembly after making sure that the packing is facing the front of the vehicle as shown in the illustration.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the 2 O-rings to the cooler evaporator sub-assembly.

NOTICE:
Keep the O-rings and O-ring fitting surfaces free from dirt or any foreign objects.

(d) Engage the clamp and install the cooler evaporator sub-assembly with the No. 1 cooler thermistor.

HINT
Completely cover the tube with the grommet.

(e) Engage the 5 claws.

(f) Install the plate cover with the 6 screws.

5. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY (for TMMC Made)

(a) Engage the 4 claws to install the evaporator insulator as shown in the illustration.

Text in Illustration

HINT
Completely cover the tube with the grommet.

6. INSTALL ASPIRATOR PIPE

(a) Engage the 2 claws and clamp to install the aspirator pipe.

7. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMC Made)

(a) Install the heater radiator unit sub-assembly as shown in the illustration.

(b) Install the clamp with the screw.

8. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMMC Made)

(a) Install the heater radiator unit sub-assembly as shown in the illustration.

(b) Install the clamp with the screw.

9. INSTALL NO. 2 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMC Made)

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

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10. INSTALL NO. 2 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMMC Made)

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

Text in Illustration

11. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY (for TMC Made)

(a) Engage the 2 claws.

(b) Install the air conditioning radiator assembly with the 2 screws.

12. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY (for TMMC Made)

(a) Install the 6 screws and air conditioning radiator assembly to the blower assembly with cooler evaporator sub-assembly.

13. INSTALL COOLER EXPANSION VALVE (for TMC Made)

(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)

14. INSTALL COOLER EXPANSION VALVE (for TMMC Made)

(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)

15. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for TMC Made)

(a) Connect each connector.

(b) Engage each clamp to install the air conditioning harness assembly.

16. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for TMMC Made)

(a) Connect each connector.

(b) Engage each clamp to install the air conditioning harness assembly.

17. INSTALL NO. 5 AIR DUCT SUB-ASSEMBLY

(a) Engage the guide and 2 claws to install the No. 5 air duct sub-assembly as shown in the illustration.

18. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

(a) Engage the guide and 2 claws to install the No. 3 air duct sub-assembly as shown in the illustration.

19. INSTALL ID CODE BOX (IMMOBILISER CODE ECU) Installation