Up to 08/2009

HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY

1. INSTALL NO. 1 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMC Made)

(a) Install the No. 1 air mix damper servo sub-assembly with the 3 screws.

2. INSTALL NO. 1 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMMC Made)

(a) Install the No. 1 air mix damper servo sub-assembly with the 3 screws.

3. INSTALL NO. 1 COOLER THERMISTOR Installation

4. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY (for TMC Made)

(a) Engage the 4 claws to install the evaporator insulator as shown in the illustration.

Text in Illustration

NOTICE:
Install the evaporator insulator to the cooler evaporator sub-assembly after making sure that the packing is facing the front of the vehicle as shown in the illustration.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the 2 O-rings to the cooler evaporator sub-assembly.

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

(d) Engage the clamp and install the cooler evaporator sub-assembly with the No. 1 cooler thermistor.

HINT
Completely cover the tube with the grommet.

(e) Engage the 5 claws.

(f) Install the plate cover with the 6 screws.

5. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY (for TMMC Made)

(a) Engage the 4 claws to install the evaporator insulator as shown in the illustration.

Text in Illustration

HINT
Completely cover the tube with the grommet.

6. INSTALL ASPIRATOR PIPE

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

7. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMC Made)

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

(b) Install the clamp with the screw.

8. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMMC Made)

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

(b) Install the clamp with the screw.

9. INSTALL NO. 2 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMC Made)

(a) Using the reference point, install the No. 2 air mix damper servo sub-assembly with the 2 screws.

Text in Illustration

10. INSTALL NO. 2 AIR MIX DAMPER SERVO SUB-ASSEMBLY (for TMMC Made)

(a) Using the reference point, install the No. 2 air mix damper servo sub-assembly with the 2 screws.

Text in Illustration

11. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY (for TMC Made)

(a) Engage the 2 claws.

(b) Install the air conditioning radiator assembly with the 2 screws.

12. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY (for TMMC Made)

(a) Install the 6 screws and air conditioning radiator assembly to the blower assembly with cooler evaporator sub-assembly.

13. INSTALL COOLER EXPANSION VALVE (for TMC Made)

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

Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

14. INSTALL COOLER EXPANSION VALVE (for TMMC Made)

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

Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

15. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for TMC Made)

(a) Connect each connector.

(b) Engage each clamp to install the air conditioning harness assembly.

16. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for TMMC Made)

(a) Connect each connector.

(b) Engage each clamp to install the air conditioning harness assembly.

17. INSTALL NO. 5 AIR DUCT SUB-ASSEMBLY

(a) Engage the guide and 2 claws to install the No. 5 air duct sub-assembly as shown in the illustration.

18. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

(a) Engage the guide and 2 claws to install the No. 3 air duct sub-assembly as shown in the illustration.

19. INSTALL ID CODE BOX (IMMOBILISER CODE ECU) Installation