REASSEMBLY

PROCEDURE

1. INSTALL NO. 1 COOLER THERMISTOR

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2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Install a new No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor to the upper heater case. NOTICE: When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

(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.

Compressor Oil:

ND-OIL 11 or equivalent

(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 COOLING UNIT PARTS

(a) Install the cooling unit parts.

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. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Insert the 3 links of the air conditioning radiator assembly into the grooves of the No. 3 air conditioning radiator damper servo sub-assembly as shown in the illustration.

*a Link

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

9. INSTALL NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

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

*a Reference Point

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

(a) 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.

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

*a Reference Point

11. 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

12. INSTALL HEATER COVER

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13. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Engage each clamp.

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

14. 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.

15. INSTALL BLOWER ASSEMBLY

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16. INSTALL ASPIRATOR

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

17. INSTALL NO. 2 AIR DUCT

(a) Engage the 3 claws to temporarily install a new No. 2 air duct.

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

18. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

(a) Engage the 4 claws to install the No. 2 air duct sub-assembly.

19. INSTALL NO. 4 HEATER TO REGISTER DUCT SUB-ASSEMBLY

(a) Engage the 6 claws.

(b) Install the No. 4 heater to register duct sub-assembly with the 2 screws.