AIR CONDITIONING UNIT > REASSEMBLY

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1. INSTALL NO. 1 COOLER THERMISTOR


I104990E01

  1. Install front evaporator temperature sensor as shown in the illustration.

    Standard:
    Part
    		Length
    *1
    		48 to 52 mm (1.890 to 2.047 in.)
    *2
    		20.9 mm (0.823 in.)
    *3
    		34.3 mm (1.350 in.)

    NOTICE:
    1. Be sure to insert the sensor only once because reinserting it will not allow it to be firmly secured.
    2. When reusing the evaporator, insert the sensor one row next to the one that was used previously (*4 in the illustration).
    3. After inserting the sensor, do not apply excessive force to the wire.
    4. Directly insert the sensor until the edge of the plastic case "*5" comes into contact with the evaporator "*6".



2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

HINT:
If a new cooler evaporator is installed, add compressor oil to the cooler evaporator as follows.

Capacity:
Add 40 cc (1.35 fl. oz.)

Compressor oil:
ND-OIL8 or equivalent.

  1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings onto the cooler evaporator.

    Compressor oil:
    ND-OIL 8 or equivalent

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



    I104910

  1. Install the cooler evaporator together with the cooler thermistor as a set.



    I104908

  1. Engage the 2 claws and install the heater case (pipe cover).



    I104906

  1. Engage the 10 claws and install the heater case (lower case).



    I105017

  1. Install the new protector.



3. INSTALL CLEAN AIR FILTER


I104904

  1. Install the clean air filter.



4. INSTALL AIR FILTER CASE


I104902

  1. Engage the claw and install the air filter case.



5. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)


I104900

  1. Engage the 4 claws and install the air conditioning harness.



6. INSTALL MODE DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


I104899E01

  1. Align the reference position and the claw, and then install the mode damper servo.
    Text in Illustration 
    *1
    		Reference position



7. INSTALL HEATER ACCESSORY ASSEMBLY


I104898

  1. Engage the 3 claws and install the heater accessory.

  1. Tighten the screw.



8. INSTALL DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


I104897E01

  1. Align the reference position and the claw, and then install the damper servo.
    Text in Illustration 
    *1
    		Reference position



9. INSTALL AIR MIX DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


I105014E01

  1. Align the reference position and the claw, and then install the air mix damper servo.
    Text in Illustration 
    *1
    		Reference position



10. INSTALL NO. 2 HEATER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)


I104919E01

  1. Align the heater control cable gear and unit gear in the FACE position.
    Text in Illustration 
    *1
    		FACE position

  1. Engage the claw and install the heater control cable.



11. INSTALL AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)


I104918E01

  1. Align the reference position and the claw, and then install the air inlet damper cable.
    Text in Illustration 
    *1
    		Reference position



12. INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)


I104934

  1. Engage the claw, 2 guides and install the air mix damper control cable onto the air conditioner unit.

  1. Engage the claw and install the air mix damper control cable.



13. INSTALL NO. 1 INSTRUMENT PANEL MOUNTING BRACKET


I104895

  1. Install the instrument panel mounting bracket with the screw.



14. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


I104894

  1. Install the air conditioning amplifier with the clip.



15. INSTALL COOLER EXPANSION VALVE


I104893

  1. Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts.

    Torque:
    3.5 N*m{ 36 kgf*cm , 31 in.*lbf }



16. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY


I104892

  1. Install the heater radiator unit.



17. INSTALL NO. 1 COOLER COVER


I104890

  1. Engage the 2 claws and install the cooler cover.



18. INSTALL QUICK HEATER ASSEMBLY (for Cold Area Specification Vehicles)


I104913

  1. Install the quick heater with the 2 screws.



19. INSTALL BLOWER W/FAN MOTOR SUB-ASSEMBLY


I104834

  1. Install the blower w/fan motor with the 3 screws.



20. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (except Cold Area Specification Vehicles)


I105075

  1. Engage the 3 claws and install the air duct.



21. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (except Cold Area Specification Vehicles)

HINT:
Use the same procedure as for the No. 2 side.



22. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for Cold Area Specification Vehicles)


I105076

  1. Engage the 3 claws and install the air duct.



23. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for Cold Area Specification Vehicles)

HINT:
Use the same procedure as for the No. 2 side.