REASSEMBLY

PROCEDURE

1. INSTALL NO. 1 COOLER THERMISTOR

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2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Install the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case.

(b) Engage the clamp.

(c) Engage the 10 claws to install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case.

(d) Install the 2 screws.

3. INSTALL COOLER EXPANSION VALVE

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

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

NOTICE:

Keep the O-rings and O-ring fitting surfaces free of foreign matter.

(c) Using a 4 mm hexagon socket wrench, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N·m {36 kgf·cm, 31 in·lbf}

4. INSTALL GROMMET SUB-ASSEMBLY

(a) Install the grommet sub-assembly.

5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

Install in this Direction

(a) Install the heater radiator unit sub-assembly as shown in the illustration.

6. INSTALL HEATER CLAMP

(a) Engage the 3 claws to install the heater clamp.

7. INSTALL HEATER PIPE GROMMET

(a) Install the heater pipe grommet as shown in the illustration. NOTICE: Install the heater pipe grommet with the arrow facing up.

*a Reference Point

8. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Dual Type)

(a) Using the reference points, install the No. 2 air conditioning radiator damper servo sub-assembly with the 2 screws.

*a Reference Point

9. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) for Single Type:

(1) Align each gear on the air conditioning radiator assembly as shown in the illustration, and then check that the gears of the No. 1 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.

(2) Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.

(b) for Dual Type:

(1) Align each gear on the air conditioning radiator assembly as shown in the illustration, and then check that the gears of the No. 1 air conditioning radiator damper servo sub-assembly are aligned as shown in the illustration.

(2) Using the reference points, install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.

*a Reference Point

10. INSTALL DRAIN COOLER HOSE

(a) Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.

*a Hose Notch *b Rib

11. INSTALL HEATER COVER

Install in this Direction

(a) Install the heater cover as shown in the illustration.

(b) Install the screw.

12. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) for Single Type:

(1) Engage each clamp.

(2) Connect each connector to install the air conditioning harness assembly.

(b) for Dual Type:

(1) Engage each clamp.

(2) Connect each connector to install the air conditioning harness assembly.

13. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

(a) Engage the guide to temporarily install the air conditioning amplifier assembly as shown in the illustration.

Install in this Direction

(b) Install the air conditioning amplifier assembly with the screw.

(c) Connect the connector.

14. INSTALL BLOWER ASSEMBLY

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15. INSTALL GROMMET (for Manual Air Conditioning System)

(a) Engage the 2 claws to install the grommet.

16. INSTALL ASPIRATOR (for Automatic Air Conditioning System)

(a) Engage the 2 claws and guide to install the aspirator.

17. INSTALL NO. 2 AIR DUCT

(a) Engage the 3 claws.

(b) Install a new No. 2 air duct with the screw.