Rear Air Conditioning Unit Assy

Rear Air Conditioning Unit Assy Part 1:

Rear Air Conditioning Unit Assy Part 2:

REAR AIR CONDITIONING UNIT ASSEMBLY

OVERHAUL

HINT:
- Installation is in the reverse order of removal.

1. EVACUATE REFRIGERANT HFC-134A (R134A)
2. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
3. REMOVE DECK TRIM SIDE BOARD RH
4. REMOVE DECK TRIM SIDE BOARD LH
5. REMOVE LUGGAGE COMPARTMENT TRIM COVER FRONT
6. REMOVE REAR SEAT CUSHION ASSEMBLY
7. REMOVE REAR SEAT BACK ASSEMBLY
8. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY
9. REMOVE ROOF SIDE GARNISH INNER RH
10. REMOVE ROOF SIDE GARNISH INNER LH
11. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY




12. REMOVE PIPE COOLER REFRIGERANT SUCTION A
a. Remove the bolt and pipe cooler refrigerant suction A.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

b. Remove the O-ring.

13. REMOVE A PIPE COOLER REFRIGERANT LIQUID
a. Remove the bolt and A pipe cooler refrigerant liquid.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

b. Remove the O-ring.




14. REMOVE AIR DUCT NO.3
a. Remove air duct No.3.




15. REMOVE AIR DUCT NO.5
a. Remove air duct No.5.




16. REMOVE AIR DUCT NO.1
a. Release the claw and remove air duct No.1.




17. REMOVE AIR DUCT NO.2
a. Release the claw and remove air duct No.2.




18. REMOVE AIR DUCT NO.4
a. Release the claw and remove air duct No.4.

19. REMOVE REAR AIR CONDITIONING UNIT ASSEMBLY




a. w/ cooling box models:
Remove the 4 cool box set bolts.




b. Disconnect the connector.
c. Remove the 2 nuts and 2 bolts.
d. Remove the rear air conditioner unit assembly.

20. REMOVE COOLER UNIT DRAIN HOSE NO.2
21. REMOVE REAR COOLER FILTER




22. REMOVE COOLING BOX LAMP SUB-ASSEMBLY (W/COOLING BOX MODELS)
a. Disconnect the connector.
b. Remove the screw and cooling box lamp sub-assembly.




23. REMOVE COOLER AIR DUCT NO.1
a. Remove the 2 screws and cooler air duct No.1.




24. REMOVE COOLER AIR DUCT NO.2
a. Remove the screw, clip and cooler air duct No.2.




25. REMOVE COOLING BOX ASSEMBLY
a. w/cooling box models:
Remove the 3 screws, clip and 2 ducts.

b. Disconnect the connector.
c. Remove the screw and cooling box light.
d. Remove the cooling box.




26. REMOVE COOLER AIR DUCT NO.3
a. Remove the 3 screws and cooler air duct No.3.




27. REMOVE SMOKE SENSOR
a. Disconnect the connector.
b. Remove the screw and smoke sensor.

28. REMOVE BLOWER MOTOR SUB-ASSEMBLY




a. Remove the 4 screws and rear cooling unit case.
b. Disconnect the connector.




c. Remove the 3 screws and blower motor sub-assembly.

29. REMOVE COOLING UNIT BLOWER FAN




a. Remove the nut and cooling unit blower fan.




30. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY
a. Disconnect the connector.
b. Release the claw and remove the air conditioning amplifier assembly.

31. WIRING AIR INDICATOR HARNESS SUB-ASSEMBLY NO.2




32. REMOVE BLOWER RESISTOR
a. Remove the screw and blower resister.




33. REMOVE EXHAUST DAMPER SERVOMOTOR
a. Remove the 3 screws and exhaust damper servomotor.




34. REMOVE EVAPORATOR SUB-ASSEMBLY (REAR)
a. Remove the 4 screws and cooler cover plate.
b. Remove the evaporator sub-assembly (rear).




35. REMOVE REAR COOLING UNIT EXPANSION VALVE
a. Using a hexagon wrench 5 mm (0.20 in.), remove the 2 hexagon bolts, air conditioning tube assembly and rear cooling unit expansion valve.
b. Remove the 4 O-rings from the rear cooling unit expansion valve.




36. INSTALL REAR COOLING UNIT EXPANSION VALVE
a. Sufficiently apply compressor oil to 4 new O-rings and fitting surface of the cooler expansion valve.
Compressor oil: ND-OIL 8 or equivalent
b. Install the 4 O-rings on the rear cooling unit expansion valve.
c. Using a hexagon wrench 5 mm (0.20 in.), install the rear cooling unit expansion valve, air conditioning tube assembly with the 2 hexagon bolts.

Torque: 3.5 Nm (36 kgf.cm, 31 in.lbf)

37. INSTALL A PIPE COOLER REFRIGERANT LIQUID
a. Sufficiently apply compressor oil to a new O-ring and fitting surface of the liquid tube.
Compressor oil: ND-OIL 8 or equivalent
b. Install the O-ring on the liquid tube.
c. Install the liquid tube with a bolt.

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




38. INSTALL PIPE COOLER REFRIGERANT SUCTION A
a. Sufficiently apply compressor oil to a new O-ring and fitting surface of the suction hose.
Compressor oil: ND-OIL 8 or equivalent
b. Install the O-ring on the suction hose.
c. Install the suction hose with a bolt.

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

39. CHARGE REFRIGERANT
40. WARM UP ENGINE
41. INSPECT FOR REFRIGERANT LEAKAGE