FRONT AIR CONDITIONING UNIT (for LHD) DISASSEMBLY


  1. REMOVE BLOWER ASSEMBLY

    Click here

  2. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY

    A015AHZ

    1. Remove the screw and duct.

  3. REMOVE NO. 5 AIR DUCT SUB-ASSEMBLY

    A015DPI

    1. Remove the screw and duct.

  4. REMOVE ASPIRATOR (for Automatic Air Conditioning System)

    A0159MS

    1. Detach the 2 claws and remove the aspirator.

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

    A015DD4

    1. Detach the clamp.

    2. Using SST, remove the piping clamp.

      SST
      09870-00025

      1. A015DCCE02

        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. A0156FXE04

        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)


    1. Remove the 2 screws.

    2. A01589T

      Detach the 3 clamps and remove the quick heater assembly (PTC heater assembly).

  7. REMOVE AIR CONDITIONER HARNESS


    1. Disconnect the connectors.

    2. Detach the clamps and remove the harness.

      A0155NKE02
      Text in Illustration
      *A for Automatic Air Conditioning System *B for 4 Zone Type

  8. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY

    A0156HT

    1. Remove the screw and radiator bracket.

    2. Remove the radiator.

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

    A0159SU

    1. Remove the packing.

    2. A015A2V

      Remove the butyl tape.

    3. A0157UX

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

    4. A015BCJ

      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. A0155WD

      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)

    A015BGQ

    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)

    A015B6E

    1. Remove the packing.

    2. A0156OR

      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)

    A015CWO

    1. Remove the 3 screws and servo motor.

  13. REMOVE SERVO MOTOR

    A015CTR

    1. Remove the 4 screws and servo motor unit.

    2. A01559R

      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. A01581P

      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. A015E7S

      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

    A015BEW

    1. Remove the 4 screws and servo motor unit.

    2. A015AXR

      Detach the 3 claws and remove the plate.

      Note

      Be careful not to damage the claw of the plate.

    3. A015DAM

      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. A0157RG

      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)

    A015B55

    1. Remove the 3 screws and servo motor unit.

    2. A0159U9

      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. A015DB9

      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.

      A01579I

  17. REMOVE FRONT EVAPORATOR TEMPERATURE SENSOR

    A015BC9

    1. Remove the front evaporator temperature sensor.