Disassembly & Reassembly

DISASSEMBLY

1. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY




a. Remove the packing from the A/C tube.




b. Using a 4 mm hexagon wench, remove the 2 hexagon bolts and A/C tube.
c. Remove the 2 O-rings from the A/C tube.

2. REMOVE COOLER EXPANSION VALVE




a. Remove the cooler expansion valve from the cooler evaporator.

3. REMOVE AIR OUTLET CONTROL SERVOMOTOR RH




a. Disconnect the connector.
b. Remove the 3 screws and servomotor.

4. REMOVE AIR MIX CONTROL SERVOMOTOR RH




a. Remove the 3 clamps and connector and disconnect the wire harness.




b. Remove the 2 screws and heater piping cover.




c. Remove the 3 screws and air servomotor.

5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY




a. Disconnect the 2 connectors and detach the 2 clamps.




b. Detach the 4 clamps and then disconnect the wire harness.
c. Remove the A/C harness as shown in the illustration.

6. REMOVE AIR OUTLET CONTROL SERVOMOTOR LH




a. Remove the 2 screws and air duct.




b. Remove the 4 screws and servomotors.




c. Remove the 3 screws.
d. Detach the claw and remove the air outlet control servomotor.

7. REMOVE AIR MIX CONTROL SERVOMOTOR LH




a. Remove the 3 screws.
b. Release the claw and remove the servomotor.

8. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY




a. Remove the screw and clamp.
b. Remove the radiator unit.

9. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY




a. Remove the 5 screws.
b. Release the 3 claws and remove the air duct case.




c. Remove the cooler evaporator from the heater case.
d. Remove the 2 O-rings from the cooler evaporator.

REASSEMBLY

1. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator.

Compressor oil: ND-OIL or equivalent




b. Install the 2 O-rings on the cooler evaporator.




c. Install the air duct with the 3 claws and 5 screws.

2. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY




a. Install the clamp with the screw and install the heater radiator unit.

3. INSTALL AIR OUTLET CONTROL SERVOMOTOR LH




a. Install the air mix control servomotor with the 3 screws.




b. Temporarily install the drive gear to the air outlet control servomotor. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servomotor.

NOTE:
- If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the drive gear, adjust the driven gear, and reinstall the drive gear.
- The number of gear teeth, from the standard position, varies according to the stop position of the air outlet control servomotor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
- If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servomotor may not operate normally.

4. INSTALL AIR MIX CONTROL SERVOMOTOR LH




a. Install the air mix control servomotor with the 3 screws.
b. Install the drive gear to the air mix control servomotor.
c. Temporarily install the mode damper servo so that the levers fit into each groove.




d. Slightly lift the mode damper servo. Check that the drive gear and driven gear are engaged at a point with the same number of gear teeth from the standard position from the view indicated by arrow (A).

NOTE:
- If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, lift the mode damper to adjust the driven gear and reinstall the mode damper servo.
- If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the mode damper servo may not operate normally.

e. Install the mode damper with the 4 screws.




f. Install the air duct with the 2 screws.

5. INSTALL AIR CONDITIONING HARNESS ASSEMBLY




a. Attach the 4 clamps to install the wire harness.
b. Install the A/C harness as shown in the illustration.




c. Connect the 2 connectors and attach the clamp.

6. INSTALL AIR MIX CONTROL SERVOMOTOR RH




a. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Temporarily install the air mix control servomotor.

NOTE:
- If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the air mix control servomotor to adjust the driven gear and reinstall the air mix control servomotor.
- The number of gear teeth, from the standard position, varies according to the stop position of the air mix control servomotor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position.
- If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air mix control servomotor may not operate normally.

b. Install the air mix control servomotor with the 3 screws.

7. INSTALL AIR OUTLET CONTROL SERVOMOTOR RH




a. Install the servomotor with the 3 screws.
b. Connect the connector.

8. INSTALL COOLER EXPANSION VALVE




a. Install the cooler expansion valve to the cooler evaporator.

9. INSTALL AIR CONDITIONING TUBE AND ACCESSORY




a. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the A/C tube.

Compressor oil: ND-OIL or equivalent

b. Install the 2 O-rings on the A/C tube.
c. Using a 4 mm hexagon wrench, install the A/C tube with the 2 hexagon bolts.

Torque: 3.5 N.m (35 kgf.cm, 30 in.lbf)




d. Install a new packing.