Disassembly and Reassembly

A/C UNIT DISASSEMBLY

1. REMOVE AIR MIX SERVOMOTORS
a. Disconnect the connector.
b. Remove the 6 screws and the both servomotors.

2. REMOVE WATER VALVE CONTROL SERVOMOTOR
a. Disconnect the connector.
b. Remove the 2 screws and servomotor.

3. REMOVE AIR OUTLET SERVOMOTOR
(Driver side)
a. Remove the 3 screws and A/C unit bracket.
b. Disconnect the connector.
c. Remove the 3 screws and the servomotor.

4. REMOVE ASPIRATOR
Remove the screw and aspirator.

5. REMOVE COOL AIR BYPASS DAMPER CONTROL SERVOMOTORS
a. Disconnect the connectors.
b. Disconnect the damper control cable.
c. Remove the 4 screws and the both servomotors.

6. REMOVE HEATER RADIATOR
a. Remove the 3 screws and clamps.
b. Pull out the heater radiator.

7. REMOVE EVAPORATOR
a. Using a hexagon wrench. remove the 3 bolts and separate the evaporator and tubes.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

ASSEMBLY HINT: Lubricate 2 new O-rings with compressor oil and install the tubes.

b. Remove the 7 screws and the evaporator cover.
c. Pull out the evaporator.

ASSEMBLY HINT: If evaporator was replaced, add compressor oil to the compressor.

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

8. REMOVE AIR OUTLET SERVOMOTOR
(Passenger side)
a. Disconnect the connector.
b. Remove the 3 screws and servomotor.

9. REMOVE EVAPORATOR TEMPERATURE SENSOR
Pull out the sensor from the evaporator.

10. REMOVE PRESSURE REGULATOR VALVE
Using a hexagon wrench, remove the bolt and separate the liquid tube and valve.
Torque: 5.4 N.m (55 kgf.cm. 48 in.lbf)

ASSEMBLY HINT: Lubricate a new O-ring with compressor oil and install the tubes.





11. REMOVE EXPANSION VALVE
a. Remove the packing and thermistor holder.
b. Loosen the 2 union nut expansion valve.
Torque:
19 mm nut: 14 N.m (140 kgf.cm. 10 ft.lbf)
24 mm nut: 23 N.m (230 kgf.cm, 17 ft.lbf)

ASSEMBLY HINT: Lubricate 2 new O-rings with compressor oil and install the tubes

12. REMOVE VENT AIR DUCT
Remove the 7 screws and duct.





13. REMOVE HEATER CASE
a. Remove the 7 screws. clip and heater case with mode seal.
b. Remove the 2 screws and mode seal case from heater case.
c. Using a screwdriver, disconnect the 3 claws and separate the driver and passenger heater case.

DISASSEMBLY HINT: Tape the screwdriver tip before use.

A/C UNIT ASSEMBLY
Assembly is in the reverse order of disassembly.