AIR CONDITIONING UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE BLOWER ASSEMBLY

    Click here

  2. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A000ZC7

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

  3. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A00104V

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

  4. REMOVE COOL AIR BYPASS SERVO MOTOR LH

    A000VA8E01

    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. A000U2P

      Disconnect the connector.

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

  5. REMOVE COOL AIR BYPASS SERVO MOTOR RH

    A000VW3E01

    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. A000WHR

      Disconnect the connector.

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

  6. REMOVE AIR MIX SERVO MOTOR LH (Cool)


    1. A000YJY

      Disconnect the connector.

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

  7. REMOVE AIR MIX SERVO MOTOR RH (Cool)


    1. A000YQE

      Disconnect the connector.

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

  8. REMOVE AIR OUTLET SERVO MOTOR LH (Face)

    A000U7EE07

    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. A000Z74

      Detach the 3 claws and remove the lever.

    3. A000UI0

      Disconnect the connector.

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

  9. REMOVE AIR OUTLET SERVO MOTOR RH (Face)

    A000V24E02

    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. A000Z99

      Detach the claw and remove the lever.

    3. A000XED

      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)

    A000XSWE01

    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. A000WQ7

      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)

    A000VQRE05

    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. A000TD9

      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)

    A000VPCE02

    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. A000UDC

      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)

    A000XVNE02

    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. A000ZHN

      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. A000YM0

      Disconnect the connector.

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

  15. REMOVE AIR MIX SERVO MOTOR RH (Hot)


    1. A000VEY

      Disconnect the connector.

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

  16. REMOVE MAX HOT BYPASS SERVO MOTOR (Hot)

    A000THTE02

    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. A000YV3

      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. A000YNR

      Detach the claw and remove the main plate.

    2. Disconnect the connector.

    3. A000YYC

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

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


    1. A000XK2

      Detach the claw and remove the main plate.

    2. A000Y12

      Disconnect the connector.

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

  19. REMOVE QUICK HEATER ASSEMBLY

    Click here

  20. REMOVE AIR CONDITIONER HARNESS ASSEMBLY

  21. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A000ZZ1

      Remove the packing.

    2. Remove the screw and clamp.

    3. A00101L

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

  22. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. A000YB2

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

    2. A000VOB

      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. A000VRR

      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

    Click here

  24. REMOVE COOLER EXPANSION VALVE


    1. A000ZOU

      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)

    A000V2T

    1. Detach the claw and remove the lever.

    2. A000VAN

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

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

    A000U4W

    1. Detach the claw and remove the lever.

    2. A000XOL

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