Disassembly and Reassembly
DISASSEMBLY
1. REMOVE AIR DUCT NO.1
a. Release the 3 claw fittings, remove the air duct No.1.
2. REMOVE HEATER TO REGISTER DUCT CENTER
a. Release the 4 claw fittings, remove the heater to register duct center.
3. REMOVE AIR OUTLET CONTROL SERVO MOTOR
a. Remove the 3 screws and air outlet control servomotor.
4. REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSEMBLY
a. Remove the wiring air conditioning harness subassembly from the air conditioner radiator assembly.
5. REMOVE AIR MIX CONTROL SERVO MOTOR
a. Remove the 3 screws and air mix control servomotor.
6. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the screw and clamp.
b. Remove the heater radiator unit sub-assembly from the air conditioner radiator assembly.
7. REMOVE COOLER THERMISTOR NO.1
8. REMOVE BLOWER RESISTOR (Manual Air Conditioning)
a. Remove the 2 screws and blower resistor.
9. REMOVE BLOWER MOTOR CONTROL (Auto Air Conditioning)
a. Remove the 2 screws and blower motor control.
10. REMOVE WIRING AIR INDICATOR HARNESS NO.2 SUB-ASSEMBLY
a. Remove the wiring air indicator harness No.2 subassembly from the blower motor control.
11. REMOVE COOLER NO.1 PACKING
a. Remove the cooler No.1 packing.
12. REMOVE AIR CONDITIONING TUBE ASSEMBLY
a. Using a hexagon wrench 4 mm (0.16 in.) remove the 2 hexagon bolts and air conditioning tube assembly.
b. Remove the 2 O-rings from the air conditioner tube assembly.
13. REMOVE COOLER EXPANSION VALVE
a. Remove the cooler expansion valve.
14. REMOVE COOLER EVAPORATOR NO.1 SUB-ASSEMBLY
a. Release the 4 claw fittings and remove the air duct sub-assembly.
b. Remove the 11 screws and evaporator cover.
c. Remove the cooler evaporator No.1 sub-assembly from the air conditioner radiator assembly.
d. Remove the 2 O-rings from the cooler evaporator No.1 sub-assembly.
REASSEMBLY
1. INSTALL COOLER EVAPORATOR NO.1 SUB-ASSEMBLY
a. Sufficiently apply compressor oil to the 2 new Orings and fitting surface of the coder evaporator No.1 sub-assembly.
Compressor oil:
ND-OIL 8 or equivalent
b. Install the 2 O-rings on the coder evaporator No.1 sub-assembly.
c. Install the cooler evaporator No.1 sub-assembly to the air conditioning radiator assembly.
d. Install the evaporator cover with the 11 screws.
2. INSTALL COOLER EXPANSION VALVE
a. Install the cooler expansion valve to the cooler evaporator No.1 sub-assembly.
3. INSTALL AIR CONDITIONING TUBE ASSEMBLY
a. Sufficiently apply compressor oil to the 2 new Orings and fitting surface of the air conditioning tube assembly.
Compressor oil:
ND-OIL 8 or equivalent
b. Install the 2 O-rings on the air conditioning tube assembly.
c. Using a hexagon wrench 4 mm (0.15 in.), install the cooler expansion valve and 2 hexagon bolts to the cooler evaporator No.1 sub-assembly.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
4. INSTALL COOLER NO.1 PACKING
a. Install the new cooler No.1 packing.
5. INSTALL WIRING AIR INDICATOR HARNESS NO.2 SUB-ASSEMBLY
6. INSTALL BLOWER MOTOR CONTROL (Auto Air Conditioning)
a. Install the blower motor control with the 2 screws.
7. INSTALL BLOWER RESISTOR (Manual Air Conditioning)
a. Install the blower resister with the 2 screws.
8. INSTALL COOLER THERMISTOR NO.1
9. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Install the heater radiator unit sub-assembly.
b. Install the screw and clamp.
10. INSTALL AIR MIX CONTROL SERVO MOTOR
a. Install the air mix control servomotor with the 3 screws.
11. INSTALL WIRING AIR CONDITIONING HARNESS SUB-ASSEMBLY
a. Install the wiring air conditioning harness subassembly.
b. Engage the connector.
12. INSTALL AIR OUTLET CONTROL SERVO MOTOR
a. Install the air outlet control servomotor with the 3 screws .
13. INSTALL HEATER TO REGISTER DUCT CENTER
a. Engage the 4 claws to install the heater to register duct center.
14. INSTALL AIR DUCT NO.1
a. Engage the 3 claws to install the air duct No.1.