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Home >> Subaru >> 2019 >> BRZ Limited, Automatic Trans >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> HVAC System (Heater, Ventilator And A/C) >> Air Conditioner Radiator ASSY >> Assembly

Air Conditioner Radiator ASSY: Assembly

  1. Installation of cover plate
    1. Install the cover plate.
    G12591672Courtesy of SUBARU OF AMERICA, INC.
    G12591673Courtesy of SUBARU OF AMERICA, INC.
  2. Installation of cooler unit case gasket (for automatic air conditioning system)
    1. Install the cooler unit case gasket.
  3. Installation of cooler unit case gasket (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
    G08553545Courtesy of SUBARU OF AMERICA, INC.
  4. Installation of cooler blower case
    1. Install the cooler blower case on the heater case lower.
      G12591675Courtesy of SUBARU OF AMERICA, INC.
    2. Fit in the 2 claws.
    3. Install the blower case ASSY with the 4 screws.
    G12591676Courtesy of SUBARU OF AMERICA, INC.
  5. Installation of blower motor control (for automatic air conditioning system)
    1. Install the blower motor control with the 2 screws.
  6. Installation of blower register (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the blower motor control.
    G12591677Courtesy of SUBARU OF AMERICA, INC.
  7. Installation of air conditioner tube ASSY (for automatic air conditioning system)
    1. Using hexagon socket wrench 4, install the air conditioner tube ASSY with the 2 hexagon bolts.

      Standard value:T=3.5N.m {36kgf.cm} {2.6ft.lbf} 

  8. Installation of air conditioner tube ASSY (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
  9. Installation of cooler thermistor NO. 1 (for automatic air conditioning system) (Refer to INSTALLATION )
  10. Installation of cooler thermistor NO. 1 (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
    G12591678Courtesy of SUBARU OF AMERICA, INC.
  11. Installation of cooler evaporator NO. 1 (for automatic air conditioning system)
    1. Install the cooler evaporator NO. 1.
  12. Installation of cooler evaporator NO. 1 (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
    G12591679Courtesy of SUBARU OF AMERICA, INC.
  13. Installation of cooling unit case (for automatic air conditioning system)
    1. Fit in the 2 claws.
    2. Install the cooling unit case with the 7 screws.
      G12591680Courtesy of SUBARU OF AMERICA, INC.
    3. Connect the clamp.
  14. Installation of cooling unit case (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
  15. Installation of heater control cable SUB-ASSY (for manual air conditioning system)
    CAUTION:
    • Be careful that dust, dirt, etc. may not stay on grease at the gear during work.
    • Do not hold the gear with cotton gloves.
    G08553552Courtesy of SUBARU OF AMERICA, INC.
    1. Turn the pin at the cable side fully in the direction of the arrow and position the assembly to the gear hole.
      NOTE: Set to the position of MAX HOT.
      G12591682Courtesy of SUBARU OF AMERICA, INC.
    2. Hold the drive gear protrusion and turn the assembly to fit in the case cylinder.
      NOTE: Temperature control position: MAX HOT
    3. Insert the positioning pins of the control cable slowly to the end so that they fit the drive gear insertion holes to install the heater control cable SUB-ASSY.
      G12591683Courtesy of SUBARU OF AMERICA, INC.
    4. Gear replacement
      1. When replacing the drive gear, pull the plastic part of the control cable slowly for removal.
        CAUTION: Do not pull the drive gear together.
      2. Pull the drive gear slowly for removal.
      3. Turn the shaft gear counterclockwise slowly until it stops.
        CAUTION: Be careful that it is not turned excessively.
      4. Align the shaft gear and the drive gear to the reference position, and insert the drive gear into the heater case slowly.
  16. Installation of air outlet damper control cable SUB-ASSY (for manual air conditioning system)
    CAUTION:
    • Be careful that dust, dirt, etc. may not stay on grease at the gear during work.
    • Do not hold the gear with cotton gloves.
    G08553555Courtesy of SUBARU OF AMERICA, INC.
    1. Turn the pin at the cable side fully in the direction of the arrow and position the assembly to the gear hole.
      NOTE: Set to the position of DEF.
      G12591685Courtesy of SUBARU OF AMERICA, INC.
    2. Hold the drive gear protrusion and turn the assembly clockwise until it stops.
      NOTE: Mode position: DEF
    3. Insert the positioning pins of the control cable slowly to the end so that they fit the drive gear insertion holes to install the air outlet damper control cable SUB-ASSY.
    4. Gear replacement
      1. When replacing the drive gear, pull the plastic part of the control cable slowly for removal.
        CAUTION: Do not pull the drive gear together.
      2. Pull the drive gear slowly for removal.
      3. Align the mode main link and the drive gear to the reference position, and insert the drive gear into the heater case slowly.
    G12591686Courtesy of SUBARU OF AMERICA, INC.
  17. Installation of air conditioner radiator damper servo SUB-ASSY NO. 3 (for automatic air conditioning system)
    1. When replacing the air conditioner radiator damper servo SUB-ASSY NO. 3 with a new one, apply a thin coat of grease evenly to the working surface A inside the link plate rail with the amount of 5 mm out of the tube (approx. 0.1 g). Similarly, apply a thin coat of grease with the same amount also evenly on the working surface B to D.
      NOTE: After the installation of air conditioner radiator damper servo SUB-ASSY NO. 3, operate it 3 to 5 times to blend the grease.
      G12591687Courtesy of SUBARU OF AMERICA, INC.
    2. Align the link pin with the main link groove, and install air conditioner radiator damper servo SUB-ASSY NO. 3 with the 3 screws.
    G08553530Courtesy of SUBARU OF AMERICA, INC.
  18. Installation of air conditioner radiator damper servo SUB-ASSY NO. 4 (for automatic air conditioning system)
    CAUTION:
    • Be careful that dust, dirt, etc. may not stay on grease at the gear during work.
    • Do not hold the gear with cotton gloves.
    1. Turn the air mix shaft in the direction of the arrow slowly until it stops.
      CAUTION: Be careful that it is not turned excessively.
      G12591689Courtesy of SUBARU OF AMERICA, INC.
    2. Turn the air mix shaft so that portion A of the air mix shaft is aligned with the reference position of the case.
      CAUTION: Since the air mix shaft can be turned approx. 360°, be careful for the assembly.
    3. Align gear B of air conditioner radiator damper servo SUB-ASSY NO. 4 with shaft gear A.
      CAUTION: Since the air mix shaft can be turned approx. 360°, be careful for the assembly.
    4. Align potion A of the air mix shaft and shaft gear B with the reference position, and install air conditioner radiator damper servo SUB-ASSY NO. 4 with the 2 screws.
  19. Installation of air duct NO. 2
    1. Install air duct NO. 2 with the 3 screws.
    G12591690Courtesy of SUBARU OF AMERICA, INC.
  20. Installation of blower motor SUB-ASSY (with fan)
    1. Install the blower motor SUB-ASSY (with fan) with the 3 screws.
    G12591691Courtesy of SUBARU OF AMERICA, INC.
  21. Installation of air duct NO. 1
    1. Install the air duct NO. 1 with the 2 screws.
    G12591692Courtesy of SUBARU OF AMERICA, INC.
  22. Installation of cooler unit drain hose NO. 1
    1. Install the cooler unit drain hose NO. 1.
      NOTE: Align the cutout with the rib of the case.
    G12591693Courtesy of SUBARU OF AMERICA, INC.
  23. Installation of cover
    1. Fit in the 2 claws.
    2. Install the cover with the 3 screws.
    G12591694Courtesy of SUBARU OF AMERICA, INC.
  24. Installation of cooler expansion valve (for automatic air conditioning system)
    1. Apply sufficient amount of compressor oil (ND-OIL8) to two new O-rings and the fitting area of the cooler expansion valve.
    2. Install the 2 O-rings on cooler evaporator NO. 1.
      CAUTION: Do not allow the O-ring and the O-ring seal to have deposit of dirt.
      G08553523Courtesy of SUBARU OF AMERICA, INC.
    3. Install a new cooler expansion valve on the cooler evaporator No. 1.
    4. Using hexagon socket wrench 4, install the cooler expansion valve with the 2 new hexagon bolts.

      Standard value:T=3.5N.m {36kgf.cm} {2.6ft.lbf} 

      G12591696Courtesy of SUBARU OF AMERICA, INC.
    5. Install a new gasket.
    G12591697Courtesy of SUBARU OF AMERICA, INC.
  25. Installation of cooler expansion valve (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
  26. Installation of cooling unit case
    1. Fit in the 4 claws.
    2. Install the cooling unit case with the 2 screws.
    G12591698Courtesy of SUBARU OF AMERICA, INC.
  27. Installation of clean air filter
    1. Slide clean air filter in the direction of the arrow in the figure to install it.
    G12591699Courtesy of SUBARU OF AMERICA, INC.
  28. Installation of air filter case
    1. Engage the 2 claws and install the air filter case.
    G12591700Courtesy of SUBARU OF AMERICA, INC.
  29. Installation of heater radiator unit SUB-ASSY (for automatic air conditioning system)
    1. Slide the heater radiator unit SUB-ASSY in the direction of the arrow in the figure to install it.
      G12591701Courtesy of SUBARU OF AMERICA, INC.
    2. Install the clamp with the screws.
      G08553516Courtesy of SUBARU OF AMERICA, INC.
  30. Installation of heater radiator unit SUB-ASSY (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
  31. Installation of heater cover (for automatic air conditioning system)
    1. Install the heater cover with the 3 screws.
    G12591703Courtesy of SUBARU OF AMERICA, INC.
  32. Installation of heater cover (for manual air conditioning system)
    NOTE: Repeat the same installation steps for the automatic air conditioning system.
  33. Installation of air conditioner radiator damper servo SUB-ASSY NO. 5 (for automatic air conditioning system)
    CAUTION:
    • Be careful that dust, dirt, etc. may not stay on grease at the gear during work.
    • Do not hold the gear with cotton gloves.
    1. Turn the air mix shaft in the direction of the arrow slowly until it stops.
      CAUTION: Be careful that it is not turned excessively.
      G12591704Courtesy of SUBARU OF AMERICA, INC.
    2. Turn the air mix shaft so that portion A of the air mix shaft is aligned with the reference position of the case.
      CAUTION: Since the air mix shaft can be turned approx. 360°, be careful for the assembly.
    3. Align gear B of air conditioner radiator damper servo SUB-ASSY NO. 5 with shaft gear A.
      NOTE: Air mix door position: Near MAX COOL
      CAUTION: Since the air mix shaft can be turned approx. 360°, be careful for the assembly.
    4. Align portion A of the air mix shaft and shaft gear B with the reference position, and install air conditioner radiator damper servo SUB-ASSY NO. 5 with the 2 screws.
  34. Installation of air conditioner radiator damper servo SUB-ASSY NO. 1
    1. When replacing the air conditioner radiator damper servo SUB-ASSY NO. 1 with a new one, apply a thin coat of grease evenly to the side A of the lever pin with the amount of 5 mm out of tube (approx. 0.1 g).
      NOTE: After the installation of air conditioner radiator damper servo SUB-ASSY NO. 1, operate it 3 to 5 times to blend the grease.
      G12591705Courtesy of SUBARU OF AMERICA, INC.
    2. Install air conditioner radiator damper servo SUB-ASSY NO. 1 with the 2 screws.
      G08553513Courtesy of SUBARU OF AMERICA, INC.
  35. Installation of aspirator (for automatic air conditioning system)
    1. Align the fitting area of the 2 claws and portion A with the pin at the case side, and install the aspirator together with the aspirator pipe.
      G08553576Courtesy of SUBARU OF AMERICA, INC.
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