REASSEMBLY

PROCEDURE

1. INSTALL HEATER COVER

Perform this procedure only when removal/installation of the heater cover is necessary.

NOTICE:

After removing the heater cover, the heater cover itself can be reused, but the air conditioning radiator assembly cannot be reused. After the heater cover is installed, the support (triangular rib) on the air conditioning radiator assembly is crushed. Therefore, if the air conditioning radiator assembly is reused, abnormal noise may occur due to looseness.

Install in this Direction

(a) Install the heater cover to a new lower heater case as shown in the illustration.

(b) Install the screw.

2. INSTALL NO. 1 COOLER THERMISTOR

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3. 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) Attach the guide.

(c) While inserting the No. 1 cooler thermistor into the guide, attach the guide and claw as shown in the illustration.

*a	No. 1 Cooler Thermistor Lead Wire	-	-
	Secure the lead wire between the guide	-	-

(d) Install the upper heater case with No. 1 cooler evaporator sub-assembly to the lower heater case with the 2 screws.

4. INSTALL COOLER EXPANSION VALVE

(a) Remove the vinyl tape from the No. 1 cooler evaporator sub-assembly and cooler expansion valve.

(b) 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

NOTICE:

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

(c) 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.

(d) 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} NOTICE: Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

5. INSTALL COOLING UNIT PARTS

(a) Install the cooling unit parts.

6. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY

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

Install in this Direction

7. INSTALL HEATER CLAMP

(a) Attach the claw to install the heater clamp.

8. 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.

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

(a) Align the gear alignment part of the heater case with the gear alignment part of the No. 2 air conditioning radiator damper servo sub-assembly as shown in the illustration.

*a Gear Alignment Part

(b) Attach the guide.

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

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

(a) Align the fitting part and gear alignment part of the heater case with the fitting part and gear alignment part of the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

(b) Attach the guide.

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

11. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

(a) Attach the clamp and guide.

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

12. INSTALL DRAIN COOLER HOSE

(a) Align the hose notch with the rib as shown in the illustration and install the drain cooler hose. NOTICE: Do not place the rib on top of the drain cooler hose. Otherwise, water may leak into the interior.

*a Hose Notch *b Rib

13. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)

(a) Install the cooler thermistor (room temperature sensor). NOTICE: Securely insert it up to the base.

14. INSTALL ASPIRATOR

(a) Attach the claw to install the aspirator. NOTICE: Firmly push it down into the heater case until a "click" sound is heard.

(b) Attach the clamp.

15. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

(a) Attach the claw to install the No. 2 air duct sub-assembly. Firmly push it down into the heater case until a "click" sound is heard. NOTICE: If the claws are not securely pushed in, a gap may form between the heater case and duct, and air leaking from the gap may cause abnormal noise and reduced performance. Also, the audio system may be exposed to cool air, causing it to malfunction.

16. INSTALL BLOWER ASSEMBLY

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