Reassembly

AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY

1. INSTALL HEATER GROMMET

(a) Install a new heater grommet.

2. INSTALL NO. 3 COOLING UNIT PACKING

(a) Remove the release paper from the No. 3 cooling unit packing.

HINT
After removing the release paper, keep the exposed adhesive free from foreign matter.

(b) Install a new No. 3 cooling unit packing.

3. INSTALL NO. 1 COOLER THERMISTOR

(a) Install the No. 1 cooler thermistor.

NOTICE:
* Be sure to insert the thermistor only once because reinserting it into the same position will not allow it to be firmly secured.
* After inserting the thermistor, do not apply excessive force to the wire.

4. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the No. 1 cooler evaporator sub-assembly.

Compressor oil:

ND-OIL 8 or equivalent

(b) Install the 2 O-rings on the No. 1 cooler evaporator sub-assembly.

5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Install the heater radiator unit sub-assembly.

(b) Install the clamp with the screw.

6. INSTALL AIR OUTLET CONTROL SERVO MOTOR

(a) Engage the claw and install the air outlet control servo motor with the 2 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 point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servomotor.

NOTICE:
* 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 servo motor may not operate normally.

7. INSTALL AIR MIX CONTROL SERVO MOTOR

(a) Engage the claw and install the air mix control servo motor with the 2 screws.

(b) Install the drive gear to the air mix control servo motor.

(c) Temporarily install the mode damper servo assembly so that the levers fit into each groove.

(d) Slightly lift the air outlet control servo motor. 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 from the view indicated by arrow (A).

NOTICE:
* 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 air outlet control servo motor to adjust the driven gear and reinstall the air outlet control servo motor.
* 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 servo motor may not operate normally.

(e) Install the air outlet control servo motor with the 4 screws.

(f) Install the air duct with the 2 screws.

8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Install the air conditioning harness assembly.

(b) Connect the connector.

(c) Connect the 2 connectors and attach the clamp.

9. INSTALL COOLER EXPANSION VALVE

(a) Install the expansion valve.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assembly.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the 2 O-rings on the air conditioning tube assembly.

(d) Using a hexagon wrench 4 mm, install the air conditioning tube assembly with the 2 hexagon bolts.

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

(e) Install a new packing.

10. INSTALL AIR MIX CONTROL SERVO MOTOR

(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 servo motor.

NOTICE:
* 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 servo motor to adjust the driven gear and reinstall the air mix control servo motor.
* The number of gear teeth from the standard position varies according to the stop position of the air mix control servo motor. 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 servo motor may not operate normally.

(b) Install the air mix control servo motor with the 3 screws.

(c) Install the heater piping cover with the 3 screws.

(d) Engage the 4 clamps.

(e) Connect the connector.

11. INSTALL COOL AIR BY-PASS CONTROL SERVO MOTOR

(a) Install the cool air by-pass control servo motor with the 3 screws.

(b) Connect the connector.