Reassembly
HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REASSEMBLY; 2013 MY FR-S [03/2012 -]
1. INSTALL COVER PLATE
(a) Install the cover plate.
2. INSTALL COOLER UNIT CASE PACKING
(a) Install the cooler unit case packing.
3. INSTALL COOLER BLOWER CASE
(a) Install the cooler blower case from the lower heater case.
(b) Engage the 2 claws.
(c) Install the blower case assembly with the 4 screws.
4. INSTALL BLOWER RESISTOR
(a) Install the blower resistor with the 2 screws.
5. INSTALL AIR CONDITIONER TUBE ASSEMBLY
(a) Using a 4 mm hexagon wrench, install the air conditioner tube assembly with the 2 hexagon bolts.
Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
6. INSTALL NO. 1 COOLER THERMISTOR Installation
7. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Install the No. 1 cooler evaporator sub-assembly with evaporator pipe as a unit.
8. INSTALL COOLING UNIT CASE SUB-ASSEMBLY
(a) Engage the 2 claws.
(b) Install the cooling unit case sub-assembly with the 7 screws.
(c) Engage the clamp.
9. INSTALL HEATER CONTROL CABLE SUB-ASSEMBLY
NOTICE:
* When working, take care not to get dirt or dust in the gear grease.
* Do not hold gear sections while wearing cotton work gloves.
(a) Turn the pin on the cable side as far as possible in the direction of the arrow, and position it so that it matches the hole in the gear.
HINT
Set the temperature adjustment dial to MAX HOT.
(b) Hold the protrusion on the drive gear, and rotate the gear until the protrusion is aligned with the cylindrical section of the case.
HINT
Temperature adjustment dial: MAX HOT
(c) Push the control cable positioning pin in slowly until it matches the drive gear hole, and install the heater control cable sub-assembly.
(d) Replacing the drive gear.
(1) When replacing the drive gear, pull the resin portion of the control cable forward slowly and remove it.
NOTICE:
Do not pull the drive gear.
(2) Pull the drive gear forward slowly and remove it.
(3) Rotate the shaft gear counterclockwise slowly until it stops.
NOTICE:
Be sure not to turn too forcefully.
(4) Match the shaft gear and the drive gear with their specified positions, and insert the drive gear slowly into the heater case.
10. INSTALL AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY
NOTICE:
* When working, take care not to get dirt or dust in the gear grease.
* Do not hold gear sections while wearing cotton work gloves.
(a) Turn the pin on the cable side as far as possible in the direction of the arrow, and position it so that it matches the hole in the gear.
HINT
Set the blower dial to DEF.
(b) Hold the protrusion on the drive gear, and rotate the gear clockwise until it stops.
HINT
Temperature control position: DEF
(c) Push the control cable positioning pin in slowly until it matches the drive gear hole, and install the air inlet damper control cable sub-assembly.
(d) Replacing the drive gear.
(1) When replacing the drive gear, pull the resin portion of the control cable forward slowly and remove it.
NOTICE:
Do not pull the drive gear.
(2) Pull the drive gear forward slowly and remove it.
(3) Match the mode main link and the drive gear with their specified positions, and insert the drive gear slowly into the heater case.
11. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Install the No. 2 air duct sub-assembly with the 3 screws.
12. INSTALL BLOWER MOTOR WITH FAN SUB-ASSEMBLY
(a) Install the blower motor with fan sub-assembly with the 3 screws.
13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY
(a) Install the No. 1 air duct sub-assembly with the 2 screws.
14. INSTALL NO. 1 COOLER UNIT DRAIN HOSE
(a) Install the No. 1 cooler unit drain hose as shown in the illustration.
HINT
Align the notched section of the hose with the rib on the case.
15. INSTALL COVER
(a) Engage the 2 claws.
(b) Install the cover with the 3 screws.
16. INSTALL COOLER EXPANSION VALVE
(a) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces. Install the 2 O-rings to the No. 1 cooler evaporator sub-assembly.
Compressor oil:
for HFC-134a (R134a)
ND-OIL 8 or equivalent
(b) Using a 4 mm hexagon wrench, install the cooler expansion valve with packing with the 2 hexagon bolts.
Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
(c) Install the new gasket.
17. INSTALL COOLING UNIT CASE
(a) Engage the 4 claws.
(b) Install the cooling unit case with the 2 screws.
18. INSTALL CLEAN AIR FILTER
(a) Install the clean air filter as shown in the illustration.
19. INSTALL AIR FILTER CASE
(a) Engage the 2 claws to install the air filter case.
20. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Install the heater radiator unit sub-assembly as shown in the illustration.
(b) Install the clamp with the screw.
21. INSTALL HEATER COVER
(a) Install the heater cover with the 3 screws.
22. INSTALL NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
(a) Install the No. 1 air conditioning radiator damper servo sub-assembly with the 3 screws.
