FRONT AIR CONDITIONING UNIT(for LHD) DISASSEMBLY

PROCEDURE


  1. REMOVE BLOWER ASSEMBLY

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  2. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY

    A01XBN2

    1. Remove the screw and duct.

  3. REMOVE NO. 5 AIR DUCT SUB-ASSEMBLY

    A01X0WI

    1. Remove the screw and duct.

  4. REMOVE ASPIRATOR (for Automatic Air Conditioning System)

    A01X898

    1. Detach the 2 claws and remove the aspirator.

  5. REMOVE COOL BOX LIQUID TUBE (w/ Cool Box)

    A01X7FR

    1. Detach the clamp.

    2. Using SST, remove the piping clamp.

      SST
      09870-00025

      1. B001X44E02

        Attach SST to the piping clamp.

        Tech Tips

        Confirm the direction of the piping clamp claw and SST by referring to the illustration on the caution label.

      2. B001WKGE04

        Push down SST and release the clamp lock.

        Note

        Be careful not to deform the tubes when pushing SST.

      3. Pull SST slightly and push the release lever, then remove the piping clamp with SST.

      4. Remove the piping clamp from SST.

        Text in Illustration
        *1 Release Lever
        *a Push
        *b Pull

    3. Disconnect the tube.

      Note

      Cap the open fittings immediately to keep moisture or dirt out of the system.

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

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

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  7. REMOVE AIR CONDITIONER HARNESS


    1. Disconnect the connectors.

    2. Detach the clamps and remove the harness.

      B001XZWE02
      Text in Illustration
      *A for Automatic Air Conditioning System *B for 4 Zone Type

  8. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY

    A01X2Z6

    1. Remove the screw and radiator bracket.

    2. Remove the radiator.

  9. REMOVE COOLER EXPANSION VALVE (w/ Cool Box)

    A01X9XV

    1. Remove the packing.

    2. A01X1XQ

      Remove the butyl tape.

    3. A01X0NI

      Using a 4 mm hexagon wrench, remove the hexagon bolt, screw and bracket.

    4. A01WZDY

      Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and No. 1 connector tube.

    5. Remove the 2 O-rings from the No. 1 connector tube.

    6. A01XAHC

      Using a 4 mm hexagon wrench, remove the 2 hexagon bolts, No. 2 connector tube, expansion valve and No. 3 connector tube.

    7. Remove the 2 O-rings from the No. 2 connector tube.

  10. REMOVE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Cool Box)

    A01X269

    1. Remove the screw and bracket.

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

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

  11. REMOVE COOLER EXPANSION VALVE (w/o Cool Box)

    A01XBPU

    1. Remove the packing.

    2. A01X7IP

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

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

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

  12. REMOVE REAR AIR MIX DAMPER CONTROL SERVO MOTOR RH (for 4 Zone Type)

    A01WZMS

    1. Remove the 3 screws and servo motor.

  13. REMOVE SERVO MOTOR

    A01X1FT

    1. Remove the 4 screws and servo motor unit.

    2. A01X5AX

      for 4 Zone Type:

      Remove the front mode control servo motor RH.


      1. Remove the 2 screws.

      2. Detach the claw and remove the plate and servo motor.

        Note

        Be careful not to damage the claw of the plate.

    3. A01X1SJ

      Remove the control bypass damper control servo motor.


      1. Remove the 2 screws.

      2. Detach the claw and remove the plate and servo motor.

        Note

        Be careful not to damage the claw of the plate.

    4. A01X9EV

      for Automatic Air Conditioning System:

      Remove the front air mix damper control servo motor RH.


      1. Remove the 2 screws.

      2. Detach the claw and remove the plate and servo motor.

        Note

        Be careful not to damage the claw of the plate.

  14. REMOVE SERVO MOTOR

    A01X2RL

    1. Remove the 4 screws and servo motor unit.

    2. A01X9KR

      Detach the 3 claws and remove the plate.

      Note

      Be careful not to damage the claw of the plate.

    3. A01WZPP

      Remove the front mode control servo motor LH.


      1. Remove the 2 screws.

      2. Detach the claw and remove the plate and servo motor.

        Note

        Be careful not to damage the claw of the plate.

    4. A01X6CN

      for Automatic Air Conditioning System:

      Remove the front air mix damper control servo motor LH.


      1. Remove the 2 screws.

      2. Detach the claw and remove the plate and servo motor.

        Note

        Be careful not to damage the claw of the plate.

  15. REMOVE SERVO MOTOR (for Automatic Air Conditioning System)

    B001Z6L

    1. Remove the 3 screws and servo motor unit.

    2. A01X3ES

      Remove the rear mode control servo motor.


      1. Remove the 2 screws.

      2. Detach the claw and remove the plate and servo motor.

        Note

        Be careful not to damage the claw of the plate.

    3. A01X9SO

      Remove the rear air mix damper control servo motor LH.


      1. Remove the 2 screws.

      2. Detach the claw and remove the lever and servo motor.

        Note

        Be careful not to damage the claw of the lever.

  16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. Remove the 7 screws.

    2. Detach the 6 claws and remove the unit case.

    3. Remove the evaporator.

      A01X0VK

  17. REMOVE FRONT EVAPORATOR TEMPERATURE SENSOR

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