AIR CONDITIONING UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE BLOWER ASSEMBLY

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  2. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY


    1. B003YQV

      Disengage the 3 claws to remove the lower defroster nozzle assembly.

  3. REMOVE AIR HOSE


    1. B003YDK

      Remove the air hose.

  4. REMOVE ASPIRATOR PIPE


    1. B003Y24

      Disengage the 2 claws to remove the aspirator pipe.

  5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY


    1. Disconnect each connector.

      B003XS9

    2. Disengage the clamp to remove the air conditioning harness assembly.

  6. REMOVE NO. 2 COOLING UNIT PACKING


    1. B003XQV

      Remove the No. 2 cooling unit packing.

  7. REMOVE COOLER PLATE


    1. B003YGV

      Remove the cooler plate.

  8. REMOVE NO. 3 COOLING UNIT PACKING


    1. B003YCM

      Remove the No. 3 cooling unit packing.

  9. REMOVE NO. 1 COOLING UNIT PACKING


    1. B003YLK

      Remove the No. 1 cooling unit packing.

  10. REMOVE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. B003XZQ

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

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

      Note

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

  11. REMOVE COOLER EXPANSION VALVE


    1. B003XY9

      Remove the cooler expansion valve.

  12. REMOVE HEATER PACKING


    1. B003XQ1

      Remove the heater packing.

  13. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. B003Y59

      Disengage the 3 claws to remove the heater clamp.

    2. for LHD:


      1. B003XO4

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

        Note

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

    3. for RHD:


      1. B003YGS

        Remove the screw.

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

        Note

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

  14. REMOVE HEATER PIPING COVER (for RHD)


    1. B003YOR

      Remove the heater piping cover.

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


    1. B003Y86

      Remove the screw.

    2. B003YA1

      Disengage the 2 claws and remove the heater cover as shown in the illustration.

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


    1. B003XOT

      Remove the screw.

    2. B003YP6

      Disengage the 2 claws and remove the quick heater assembly as shown in the illustration.

  17. REMOVE NO. 4 COOLING UNIT PACKING


    1. B003YFW

      Remove the No. 4 cooling unit packing.

  18. REMOVE HEATER GROMMET


    1. B003Y9E

      Remove the heater grommet.

  19. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B003YDA

      Remove the 2 screws and No. 1 air conditioning radiator damper servo sub-assembly.

  20. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for RH Side)


    1. B003YJ5

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

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


    1. B003YO8

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

  22. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for LH Side)


    1. B003XXD

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

  23. REMOVE NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B003Y4W

      Remove the 2 screws and No. 5 air conditioning radiator damper servo sub-assembly.

  24. REMOVE NO. 6 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B003YII

      Remove the 2 screws and No. 6 air conditioning radiator damper servo sub-assembly.

  25. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY


    1. B003XQ5

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

  26. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. Remove the 5 screws.

      B003Y92

    2. Disengage the 5 claws to remove the air duct with No. 1 cooler evaporator sub-assembly.

    3. B003XQP

      Disengage the clamp.

    4. Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor from the air duct as shown in the illustration.

    5. B003YL2

      Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

  27. REMOVE NO. 1 COOLER THERMISTOR

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  28. REMOVE HEATER CASE SUB-ASSEMBLY


    1. Using a plier nipper (side cutters), cut the 10 claws and remove the heater case sub-assembly.

      B003XZJ