FRONT AIR CONDITIONING UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Use the same procedure for RHD and LHD vehicles.
The procedure listed below is for LHD vehicles.

PROCEDURE

PRECAUTION

Note

Make sure to perform initialization after replacing the air conditioning radiator damper servo sub-assembly. If initialization is not performed, the air conditioning unit assembly will not perform properly as the air conditioning amplifier assembly will not be able to recognize the position of the air conditioning radiator damper sub-assembly.
REMOVE BLOWER ASSEMBLY

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REMOVE ASPIRATOR
1. Detach the claw and remove the aspirator.
REMOVE COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)
1. Remove the cooler thermistor (room temperature sensor) from the aspirator.
REMOVE PACKING
1. Remove the 2 packings.
REMOVE DRAIN COOLER HOSE (for Connector)
1. Remove the drain cooler hose (for connector).
REMOVE DRAIN COOLER HOSE (for Front Passenger Side) (for LHD)
1. Remove the drain cooler hose (for front passenger side).
REMOVE DRAIN COOLER HOSE (for Front Passenger Side) (for RHD)
1. Remove the drain cooler hose (for front passenger side).
REMOVE DRAIN COOLER HOSE (for Driver's Side) (for LHD)
1. Remove the drain cooler hose (for driver's side).
REMOVE DRAIN COOLER HOSE (for Driver's Side) (for RHD)
1. Remove the drain cooler hose (for driver's side).
REMOVE HEATER GROMMET
1. *A for LHD
  
  *B for RHD
  
  Remove the heater grommet.
REMOVE COOLING UNIT PARTS
1. Remove the cooling unit parts.
REMOVE QUICK HEATER ASSEMBLY (w/ PTC Heater)
Note

Do not hold the quick heater assembly by the element or fan. Also, do not damage the quick heater assembly. (Foul odors may occur due to oil adhering to the quick heater assembly.)
1. Remove the screw.
2. Pull Directly Up
  
  Detach the claw and remove the quick heater assembly.
  
  Tech Tips
  
  If the claw of the quick heater assembly are damaged, install the screw.
REMOVE HEATER COVER (w/o PTC Heater)

Tech Tips

Use the same procedure as for the quick heater assembly.
REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
1. for LHD:
  1. Detach the claw and remove the heater clamp.
  2. Pull Directly Up
    
    Remove the heater radiator unit sub-assembly from the heater case.
    
    Note
    
    Prepare a drain pan or cloth in case the coolant leaks.
2. for RHD:
  1. Detach the claw and remove the heater clamp.
  2. Remove the screw and bracket.
  3. Pull Directly Up
    
    Remove the heater radiator unit sub-assembly from the heater case.
    
    Note
    
    Prepare a drain pan or cloth in case the coolant leaks.
REMOVE AIR CONDITIONING HARNESS ASSEMBLY
1. for LHD:
  1. Remove the screw.
  2. Detach the claw, guide and guide pin and remove the bracket.
  3. Disconnect the 8 connectors.
  4. Remove the air conditioning harness assembly from the guide.
2. for RHD:
  1. Disconnect the 8 connectors.
  2. Remove the air conditioning harness assembly from the guide.
REMOVE NO. 2 COOLER COVER
1. Detach the claw and guide pin and remove the No. 2 cooler cover.
REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Using a 4 mm hexagon socket wrench, remove the 2 hexagon bolts and air conditioning tube and accessory assembly.
2. Remove the 2 O-rings from the air conditioning tube and accessory assembly.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent the entry of moisture and foreign matter.
REMOVE COOLER EXPANSION VALVE
1. Remove the cooler expansion valve together with the No. 1 cooler cover.
2. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent the entry of moisture and foreign matter.
REMOVE NO. 1 COOLER COVER
1. Remove in this Direction
  
  Remove the No. 1 cooler cover from the cooler expansion valve.
  
  Note
  
  Seal the openings of the disconnected parts using vinyl tape to prevent the entry of moisture and foreign matter.
REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. Remove the 3 screws and No. 2 air conditioning radiator damper servo sub-assembly.
REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. for LHD:
  1. Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.
2. for RHD:
  1. Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.
REMOVE NO. 4 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. Remove the 3 screws and No. 4 air conditioning radiator damper servo sub-assembly.
REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY
1. Remove the 2 screws and guide and remove the No. 3 air conditioning radiator damper servo sub-assembly.

REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

for LHD:

Detach the clamp.

*a	Clamp	*b	Guide
*c	Guide Pin	*d	No. 1 Cooler Thermistor Lead Wire
	Detach lead wire from guide	-	-

Remove the 2 screws.
Detach the claw and guide pin and while detaching the lead wire of the No. 1 cooler thermistor from the guide, separate the heater case as shown in the illustration.

for RHD:

Detach the clamp.

*a	Clamp	*b	Guide
*c	Guide Pin	*d	No. 1 Cooler Thermistor Lead Wire
	Detach lead wire from guide	-	-

Remove the 2 screws.
Detach the claw and guide pin and while detaching the lead wire of the No. 1 cooler thermistor from the guide, separate the heater case as shown in the illustration.

*A	for LHD
*B	for RHD
	Remove in this Direction

Remove the No. 1 cooler evaporator sub-assembly.

REMOVE NO. 1 COOLER THERMISTOR

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REMOVE HEATER BRACKET

*A	for LHD
*B	for RHD
	Remove in this Direction

Remove the screw.

for RHD:
1. Detach the claw.
Detach the guide and remove the heater bracket as shown in the illustration.

REMOVE BRACKET
1. for LHD:
  1. Remove the screw, detach the guide and remove the bracket.
  2. Remove the screw, detach the guide and remove the bracket.
2. for RHD:
  1. Remove the screw, detach the guide and remove the bracket.
  2. Remove the screw, detach the guide and remove the bracket.