Disassembly and Assembly

COOLING UNIT DISASSEMBLY/ASSEMBLY




1. Disassemble in the order indicated below.
1. Resistor
2. Polyurethane foam
3. Polyurethane protector (1)
4. Polyurethane protector (2)
5. Cooler case (1)
6. Cooler case (2)
7. Polyethylene foam
8. Sensor clamp
9. A/C amplifier
10. Insulator
11. Adhesive sponge rubber
12. Sponge rubber
13. Polyurethane protector (3)
14. Polyethylene protector
15. Polyurethane protector (4)
16. Evaporator
17. Expansion valve

CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

2. Assemble in the reverse order of disassembly.

Expansion Valve Assembly Note
1. Apply compressor oil to the O-rings and connect the joint.
2. Tighten the nut of the joint by hand.
3. Tighten the joint with the specified torque with a spanner and torque wrench.




4. Assemble the heat-sensing tube as shown in the figure.
5. Route the capillary tube as shown in the figure.




6. Verify that the capillary tube is not in the shaded zone




Evaporator Assembly Note
1. Verify that the upper pipe in the evaporator does not interfere with the cooler case (1) in the shaded zone.




Adhesive Sponge Rubber Assembly Note
1. Attach the adhesive sponge rubber so that the heat sensing tube is hidden.




Insulator Assembly Note
1. Make the two insulators cross.
2. Attach the insulator so that the shaded zone of expansion valve is hidden.




A/C Amplifier Assembly Note
1. Assemble the evaporator temperature sensor as shown in the figure.




Sensor Clamp Assembly Note
1. Assemble the sensor clamp as shown in the figure.




Polyethylene Foam Assembly Note
1. Apply the adhesive to a range of 50 mm (1.97 in) from the edge of polyethylene foam, and around the drain outlet. Apply the polyethylene foam to the cooler case (2).

EVAPORATOR INSPECTION
1. Remove the cooling unit.
2. Remove the evaporator from the cooling unit.
3. Inspect for cracks, damage, and oil leakage.
- If any problems are found, replace the evaporator.
4. Inspect for bent fins.
- If any are bent, use a flathead screwdriver to straighten them.