AIR CONDITIONING UNIT DISASSEMBLY

PROCEDURE


  1. PRECAUTION

    Note

    Make sure to perform initialization after replacing the air conditioning radiator damper servo sub-assembly. If initialization is not performed, the air conditioner unit assembly will not perform properly as the air conditioning amplifier assembly will not be able to recognize the position of the air conditioning radiator damper sub-assembly.

  2. REMOVE NO. 2 AIR DUCT (for LHD)


    1. A01RK3W

      Remove the screw.

    2. Disengage the 3 claws to remove the No. 2 air duct.

  3. REMOVE NO. 1 AIR DUCT (for RHD)


    1. A01RJLT

      Remove the screw.

    2. Disengage the 3 claws to remove the No. 1 air duct.

  4. REMOVE ASPIRATOR


    1. A01RHBB

      Disengage the 2 claws to remove the aspirator.

  5. REMOVE NO. 3 INSTRUMENT PANEL WIRE (w/ PTC Heater)


    1. A01RJN6

      Disconnect the 2 connectors.

    2. Disengage the 5 clamps to remove the No. 3 instrument panel wire.

  6. REMOVE BLOWER ASSEMBLY

    Click here

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


    1. A01RK5HC01
      B004PI4 Remove in this Direction

      Remove the screw and heater cover as shown in the illustration.

  8. REMOVE NO. 2 HEATER COVER (w/ PTC Heater)


    1. A01RIG6

      Remove the screw.

    2. Disengage the claw and guide to remove the No. 2 heater cover.

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


    1. A01RI90C01
      B004PI4 Remove in this Direction

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

  10. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. for LHD:


      1. A01RK46C01
        B004PI4 Remove in this Direction

        Disconnect the connector.

      2. Remove the screw.

      3. Disengage the guide to remove the air conditioning amplifier assembly as shown in the illustration.

    2. for RHD:


      1. A01RKOHC01
        B004PI4 Remove in this Direction

        Disconnect the connector.

      2. Remove the screw.

      3. Disengage the guide to remove the air conditioning amplifier assembly as shown in the illustration.

  11. REMOVE AIR CONDITIONING HARNESS ASSEMBLY


    1. for LHD:


      1. Disconnect each connector.

        A01RH3V

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

    2. for RHD:


      1. Disconnect each connector.

        A01RKT3

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

  12. REMOVE DRAIN COOLER HOSE


    1. A01RHBE

      Remove the drain cooler hose.

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


    1. A01RK19

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

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


    1. A01RJD2

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

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


    1. A01RJUO

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

  16. REMOVE HEATER GROMMET


    1. A01RI1A

      Remove the heater grommet.

  17. REMOVE HEATER CLAMP


    1. A01RK22

      Disengage the 4 claws to remove the heater clamp.

  18. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY


    1. A01RH4FC01
      B004PI4 Remove in this Direction

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

      Note

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

  19. REMOVE COOLER EXPANSION VALVE


    1. A01RJYW

      Remove the cooling unit parts.

    2. A01RLB2

      Using a 4 mm hexagon socket wrench, remove the 2 hexagon bolts and cooler expansion valve.

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

  20. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY


    1. Remove the 2 screws.

      A01RJ0D

    2. Disengage the 10 claws to remove the upper heater case with No. 1 cooler evaporator sub-assembly from the lower heater case.

    3. A01RKZD

      Disengage the clamp.

    4. Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor from the upper heater case.

  21. REMOVE NO. 1 COOLER THERMISTOR

    Click here