AIR CONDITIONING UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE BLOWER ASSEMBLY

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  2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY


    1. B004F91

      Disengage the 3 claws to remove the lower defroster nozzle assembly.

  3. REMOVE AIR HOSE


    1. B004FDF

      Remove the air hose.

  4. REMOVE ASPIRATOR PIPE


    1. B004ERW

      Disengage the 2 claws to remove the aspirator pipe.

  5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY


    1. Disconnect each connector.

      B004EK0

    2. Disengage the clamp to remove the air conditioning harness assembly.

  6. REMOVE NO. 2 COOLING UNIT PACKING


    1. B004G9B

      Remove the No. 2 cooling unit packing.

  7. REMOVE COOLER PLATE


    1. B004EAK

      Remove the cooler plate.

  8. REMOVE NO. 3 COOLING UNIT PACKING


    1. B004FXU

      Remove the No. 3 cooling unit packing.

  9. REMOVE NO. 1 COOLING UNIT PACKING


    1. B004FP2

      Remove the No. 1 cooling unit packing.

  10. REMOVE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. B004GIE

      Using a 4 mm hexagon socket wrench, remove the 2 hexagon bolts and air conditioner tube and accessory assembly.

    2. Remove the 2 O-rings from the air conditioner tube and accessory assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  11. REMOVE COOLER EXPANSION VALVE


    1. B004F1C

      Remove the cooler expansion valve.

  12. REMOVE HEATER PACKING


    1. B004FO2

      Remove the heater packing.

  13. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B004FYK

      Disengage the 3 claws to remove the heater clamp.

    2. for LHD:


      1. B004GRC

        Remove the heater radiator unit sub-assembly as shown in the illustration.

        Note

        Prepare a drain pan or cloth in case the coolant leaks.

    3. for RHD:


      1. B004FIG

        Remove the screw.

      2. Remove the heater radiator unit sub-assembly as shown in the illustration.

        Note

        Prepare a drain pan or cloth in case the coolant leaks.

  14. REMOVE HEATER PIPING COVER (for RHD)


    1. B004G9P

      Remove the heater piping cover.

  15. REMOVE HEATER COVER (w/o PTC Heater)


    1. w/ Screw:


      1. B004FII

        Remove the screw.

    2. B004FZL

      Disengage the 2 claws and remove the heater cover as shown in the illustration.

  16. REMOVE QUICK HEATER ASSEMBLY (w/ PTC Heater)


    1. w/ Screw:


      1. B004FMC

        Remove the screw.

    2. B004FHV

      Disengage the 2 claws and remove the quick heater assembly as shown in the illustration.

  17. REMOVE NO. 4 COOLING UNIT PACKING


    1. B004FU5

      Remove the No. 4 cooling unit packing.

  18. REMOVE HEATER GROMMET


    1. B004ELN

      Remove the heater grommet.

  19. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B004GQB

      Remove the 2 screws and No. 1 air conditioning radiator damper servo sub-assembly.

  20. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RH Side)


    1. B004FSD

      Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

  21. REMOVE NO. 4 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B004F0X

      Remove the 3 screws and No. 4 air conditioning radiator damper servo sub-assembly.

  22. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LH Side)


    1. B004E61

      Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

  23. REMOVE NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B004EJD

      Remove the 2 screws and No. 5 air conditioning radiator damper servo sub-assembly.

  24. REMOVE NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B004FCF

      Remove the 2 screws and No. 6 air conditioning radiator damper servo sub-assembly.

  25. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B004E89

      Remove the 3 screws and No. 3 air conditioning radiator damper servo sub-assembly.

  26. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. Remove the 5 screws.

      B004GWJ

    2. Disengage the 5 claws to remove the air duct with No. 1 cooler evaporator sub-assembly.

    3. B004G2V

      Disengage the clamp.

    4. Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor from the air duct as shown in the illustration.

    5. B004EXD

      Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

  27. REMOVE NO. 1 COOLER THERMISTOR

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  28. REMOVE HEATER CASE SUB-ASSEMBLY


    1. Using a plier nipper (side cutters), cut the 10 claws and remove the heater case sub-assembly.

      B004GOF