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


  1. REMOVE BLOWER ASSEMBLY

    Click here

  2. REMOVE ASPIRATOR


    1. B004RAN

      Detach the claw and remove the aspirator.

  3. REMOVE COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)


    1. B004Y71

      Remove the cooler thermistor (room temperature sensor) from the aspirator.

  4. REMOVE NO. 3 COOLING UNIT PACKING


    1. B004UPY

      Remove the No. 3 cooling unit packing.

  5. REMOVE NO. 2 COOLER UNIT DRAIN HOSE


    1. B004WFL

      Remove the No. 2 cooler unit drain hose.

  6. REMOVE DRAIN COOLER HOSE (for Front Passenger Side)


    1. B004SRA

      Remove the drain cooler hose (for front passenger side).

  7. REMOVE DRAIN COOLER HOSE (for Driver's Side)


    1. B004X8O

      Remove the drain cooler hose (for driver's side).

  8. REMOVE HEATER GROMMET


    1. B004VBJC01
      *A for LHD
      *B for RHD

      Remove the heater grommet.

  9. REMOVE COOLING UNIT PARTS


    1. B004UXL

      Remove the cooling unit parts.

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


    1. B004RYUC01
      *A for LHD
      *B for RHD

      Remove the screw.

    2. B004TX8C01
      *A for LHD
      *B for RHD

      Detach the claw and remove the quick heater assembly.

      Note


      • B004YRKC01
        *a Element
        *b Fin

        Do not hold the quick heater assembly by the element or fin. Also, do not damage the quick heater assembly.

      • Foul odors may occur due to oil adhering to the quick heater assembly.

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

    Tech Tips

    Use the same procedure as for the quick heater assembly.

  12. REMOVE NO. 3 COOLING UNIT BRACKET (for RHD)


    1. B004W5X

      Remove the screw and No. 3 cooling unit bracket.

  13. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B004RSDC01
      *A for LHD
      *B for RHD

      Detach the claw and remove the heater clamp.

    2. B004S45

      Disconnect the 2 connectors.

    3. Detach the guide.

    4. B004TIX

      Remove the heater radiator unit sub-assembly from the heater case.

      Note

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

  14. REMOVE PACKING


    1. B004V6G

      Remove the packing.

  15. REMOVE AIR CONDITIONING HARNESS ASSEMBLY


    1. for LHD:


      1. Disconnect the 14 connectors.

        B004XWR

    2. for RHD:


      1. Disconnect the 14 connectors.

        B004T26

    3. Remove the air conditioning harness assembly from the guide.

  16. REMOVE NO. 2 COOLER COVER


    1. B004TXA

      Detach the claw and guide pin and remove the No. 2 cooler cover.

  17. REMOVE AIR CONDITIONING TUBE ASSEMBLY


    1. B004XIH

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

    2. Remove the 2 O-rings from the air conditioning tube assembly.

      Note

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

  18. REMOVE COOLER EXPANSION VALVE


    1. B004RRM

      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.

  19. REMOVE NO. 1 COOLER COVER


    1. B004Y8LC01
      B004RMI 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.

  20. REMOVE NO. 3 COOLING UNIT BRACKET (for LHD)


    1. B004TC0C01
      *a Guide
      *b Guide pin

      Remove the screw.

    2. Detach the claw, guide and guide pin and remove the No. 3 cooling unit bracket.

  21. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. B004TSV

      Remove the 2 screws and guide and remove the No. 3 air conditioning radiator damper servo sub-assembly.

  22. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B004WHX

      Remove the 3 screws and No. 2 air conditioning radiator damper servo sub-assembly.

  23. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    1. B004W8K

      Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.

  24. REMOVE NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. B004WB2

      Remove the 3 screws and No. 6 air conditioning radiator damper servo sub-assembly.

  25. REMOVE NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    1. B004YPL

      Remove the 3 screws and No. 5 air conditioning radiator damper servo sub-assembly.

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


    1. B004TZR

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

  27. REMOVE NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    1. B004U43

      Remove the 3 screws and No. 6 air conditioning radiator damper servo sub-assembly.

  28. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. B004XBG

      Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.

  29. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LHD)


    1. B004RO0

      Remove the 2 screws and guide and remove the No. 3 air conditioning radiator damper servo sub-assembly.

  30. REMOVE NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RHD)


    1. B004UZZ

      Remove the 3 screws and No. 5 air conditioning radiator damper servo sub-assembly.

  31. REMOVE HEATER AIR DAMPER ASSEMBLY


    1. Remove the screw.

      B004TFV

      1. Detach the claw and guide pin and remove the heater air damper assembly.

  32. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. for LHD:


      1. Detach the clamp.

        B004TQ2C01
        *a Clamp *b Guide
        *c Guide Pin *d No. 1 Cooler Thermistor Lead Wire
        B004RMI Detach lead wire from guide - -

      2. Remove the 2 screws.

      3. 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.

    2. for RHD:


      1. Detach the clamp.

        B004RGJC01
        *a Clamp *b Guide
        *c Guide Pin *d No. 1 Cooler Thermistor Lead Wire
        B004RMI Detach lead wire from guide - -

      2. Remove the 2 screws.

      3. 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.

    3. B004XIL

      Remove the No. 1 cooler evaporator sub-assembly.

  33. REMOVE NO. 1 COOLER THERMISTOR

    Click here

  34. REMOVE NO. 1 COOLING UNIT BRACKET


    1. B004Y14C01
      *A for LHD
      *B for RHD

      Remove the screw, detach the guide and remove the No. 1 cooling unit bracket.

  35. REMOVE NO. 2 COOLING UNIT BRACKET


    1. B004WAKC01
      *A for LHD
      *B for RHD

      Remove the screw, detach the guide and remove the No. 2 cooling unit bracket.

  36. REMOVE NO. 4 COOLING UNIT PACKING


    1. B004T7V

      Remove the No. 4 cooling unit packing.