AIR CONDITIONING UNIT(for Front Side) DISASSEMBLY

PROCEDURE


  1. REMOVE BLOWER ASSEMBLY

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  2. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A001AAJ

      Detach the 4 claws and remove the No. 1 air duct sub-assembly.

  3. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A001CPW

      Detach the 4 claws and remove the No. 2 air duct sub-assembly.

  4. REMOVE COOL AIR BYPASS SERVO MOTOR LH

    A001E25E01

    1. When reusing the cool air bypass servo motor LH:

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001ABP

      Disconnect the connector.

    3. Remove the 2 screws and cool air bypass servo motor LH.

  5. REMOVE COOL AIR BYPASS SERVO MOTOR RH

    A001CNHE01

    1. When reusing the cool air bypass servo motor RH:

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001E9S

      Disconnect the connector.

    3. Remove the 2 screws and cool air bypass servo motor RH.

  6. REMOVE AIR MIX SERVO MOTOR LH (Cool)


    1. A001D33

      Disconnect the connector.

    2. Remove the 2 screws and air mix servo motor LH (cool).

  7. REMOVE AIR MIX SERVO MOTOR RH (Cool)


    1. A001B2B

      Disconnect the connector.

    2. Remove the 2 screws and air mix servo motor RH (cool).

  8. REMOVE AIR OUTLET SERVO MOTOR LH (Face)

    A001D8PE05

    1. When reusing the air outlet servo motor LH (Face):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001DGC

      Detach the 3 claws and remove the lever.

    3. A001EUN

      Disconnect the connector.

    4. Remove the 2 screws and air outlet servo motor LH (Face).

  9. REMOVE AIR OUTLET SERVO MOTOR RH (Face)

    A001ES5E02

    1. When reusing the air outlet servo motor RH (Face):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001DGH

      Detach the claw and remove the lever.

    3. A001EYH

      Disconnect the connector.

    4. Remove the 2 screws and air outlet servo motor RH (Face).

  10. REMOVE AIR OUTLET SERVO MOTOR LH (Front A/C Rear Air Flow)

    A001902E01

    1. When reusing the air outlet servo motor LH (front A/C rear air flow):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001AIE

      Disconnect the connector.

    3. Remove the 2 screws and air outlet servo motor LH (front A/C rear air flow).

  11. REMOVE AIR OUTLET SERVO MOTOR RH (Front A/C Rear Air Flow) (for 4 Zone Type)

    A0019O4E04

    1. When reusing the air outlet servo motor RH (front A/C rear air flow):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001DLA

      Disconnect the connector.

    3. Remove the 2 screws and air outlet servo motor RH (front A/C rear air flow).

  12. REMOVE AIR MIX SERVO MOTOR LH (Front A/C Rear Air Flow) (for 4 Zone Type)

    A001AU4E02

    1. When reusing the air mix servo motor LH (front A/C rear air flow):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001DQE

      Disconnect the connector.

    3. Remove the 2 screws and air mix servo motor LH (front A/C rear air flow).

  13. REMOVE AIR MIX SERVO MOTOR RH (Front A/C Rear Air Flow)

    A001A1FE02

    1. When reusing the air mix servo motor RH (front A/C Rear Air Flow):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001BR4

      Disconnect the connector.

    3. Remove the 2 screws and air mix servo motor RH (front A/C Rear Air Flow).

  14. REMOVE AIR MIX SERVO MOTOR LH (Hot)


    1. A001ATI

      Disconnect the connector.

    2. Remove the 2 screws and air mix servo motor LH (Hot).

  15. REMOVE AIR MIX SERVO MOTOR RH (Hot)


    1. A001C0H

      Disconnect the connector.

    2. Remove the 2 screws and air mix servo motor RH (Hot).

  16. REMOVE MAX HOT BYPASS SERVO MOTOR (Hot)

    A001F54E02

    1. When reusing the max hot air bypass servo motor (hot):

      Place alignment marks on the moving parts and air conditioning unit as shown in the illustration.

      Text in Illustration
      *1 Alignment Marks
    2. A001EHR

      Disconnect the connector.

    3. Remove the 2 screws and max hot air bypass servo motor (hot).

  17. REMOVE AIR OUTLET SERVO MOTOR LH (Foot/Def)


    1. A001AO0

      Detach the claw and remove the main plate.

    2. Disconnect the connector.

    3. A001C77

      Remove the 3 screws and air outlet servo motor LH (foot/def).

  18. REMOVE AIR OUTLET SERVO MOTOR RH (Foot/Def)


    1. A001BEA

      Detach the claw and remove the main plate.

    2. A001EBP

      Disconnect the connector.

    3. Remove the 3 screws and air outlet servo motor RH (foot/Def).

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

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  20. REMOVE AIR CONDITIONER HARNESS ASSEMBLY

  21. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A0019DO

      Remove the packing.

    2. Remove the screw and clamp.

    3. A001BOK

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

  22. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. A001EJV

      Remove the No. 2 cooling unit packing and No. 3 cooling unit packing from the air conditioner assembly.

    2. A001DM6E01

      Remove the packing from the bracket.

    3. Remove the holding spring and detach the hook, and then remove the bracket from the air conditioner tube assembly.

    4. A0019YG

      Remove the 6 screws.

    5. Detach the 3 claws and remove the front cooling unit case (back side).

    6. Remove the No. 1 cooler evaporator sub-assembly.

  23. REMOVE NO. 1 COOLER THERMISTOR

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  24. REMOVE COOLER EXPANSION VALVE


    1. A001EDX

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

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

    3. Remove the cooler expansion valve from the evaporator.

    4. Remove the 2 O-rings from the evaporator.

  25. REMOVE MAX HOT BYPASS SERVO MOTOR (Cool) (for LHD)

    A001FQU

    1. Detach the claw and remove the lever.

    2. A001BE1

      Remove the 3 screws and max hot bypass servo motor (cool).

  26. REMOVE MAX HOT BYPASS SERVO MOTOR (Cool) (for RHD)

    A001BI9

    1. Detach the claw and remove the lever.

    2. A001ER4

      Remove the 3 screws and max hot bypass servo motor (cool).