AIR CONDITIONING UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE ASPIRATOR (for Automatic Air Conditioning System)


    1. A004KL2

      Disengage the 2 claws and remove the aspirator with aspirator pipe as a unit.

  2. REMOVE ASPIRATOR PIPE (for Automatic Air Conditioning System)


    1. A004HFK

      Remove the aspirator pipe.

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


    1. A004HTC

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

  4. REMOVE NO. 5 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004HL5

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

      Note

      When re-using the No. 5 air conditioner damper servo sub-assembly, set the temperature adjustment dial to MAX COOL before removing the sub-assembly, and then wait for 30 seconds before beginning work.

  5. REMOVE HEATER COVER (for Automatic Air Conditioning System)


    1. A004JE9

      Remove the 3 screws and heater cover.

  6. REMOVE HEATER COVER (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  7. REMOVE HEATER COVER (w/o Airbag System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  8. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004J3C

      Remove the screw and the clamp.

    2. A004KVL

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

  9. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  10. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (w/o Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  11. REMOVE AIR FILTER CASE


    1. A004I0Q

      Disengage the 2 claws and remove the air filter case.

  12. REMOVE CLEAN AIR FILTER


    1. A004JUM

      Remove the clean air filter as shown in the illustration.

  13. REMOVE COOLING UNIT CASE


    1. A004I1R

      Remove the 2 screws.

    2. Disengage the 4 claws and remove the cooling unit case.

  14. REMOVE COOLER EXPANSION VALVE (for Automatic Air Conditioning System)


    1. A004IM4

      Remove the gasket.

    2. A004J0L

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

    3. A004JWW

      Remove the 2 O-rings from the evaporator pipe.

  15. REMOVE COOLER EXPANSION VALVE (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  16. REMOVE COVER


    1. A004IFS

      Remove the 3 screws.

    2. Disengage the 2 claws and remove the cover.

  17. REMOVE NO. 1 COOLER UNIT DRAIN HOSE


    1. A004HXL

      Remove the No. 1 cooler unit drain hose.

  18. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A004HZI

      Remove the 2 screws and remove the No. 1 air duct sub-assembly.

  19. REMOVE BLOWER MOTOR WITH FAN SUB-ASSEMBLY


    1. A004HBG

      Remove the 3 screws and remove the blower motor with fan sub-assembly.

  20. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A004KLS

      Remove the 3 screws and remove the No. 2 air duct sub-assembly.

  21. REMOVE NO. 4 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004JCH

      Remove the 2 screws and remove the No. 4 air conditioning radiator damper servo sub-assembly.

      Note

      When re-using the No. 4 air conditioner damper servo sub-assembly, set the temperature adjustment dial to MAX COOL before removing the sub-assembly, and then wait for 30 seconds before beginning work.

  22. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004J86

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

  23. REMOVE AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (for Manual Air Conditioning System)


    1. A004I8C

      Disengage the 3 claws and remove the air inlet damper control cable sub-assembly.

      Note

      Hold the control cable and remove the drive gear on the unit side slowly, without pulling it.

  24. REMOVE AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (w/o Air Conditioning System)

    Tech Tips

    Use the same procedure as for the manual air conditioning system.

  25. REMOVE HEATER CONTROL CABLE SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004K8A

      Disengage the 3 claws and remove the heater control cable sub-assembly.

      Note

      Hold the control cable and remove the drive gear on the unit side slowly, without pulling it.

  26. REMOVE HEATER CONTROL CABLE SUB-ASSEMBLY (w/o Air Conditioning System)

    Tech Tips

    Use the same procedure as for the manual air conditioning system.

  27. REMOVE COOLING UNIT CASE SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004KV8

      Disengage the clamp.

    2. A004I6Z

      Remove the 7 screws.

    3. Disengage the 2 claws and remove the cooling unit case sub-assembly.

  28. REMOVE COOLING UNIT CASE SUB-ASSEMBLY (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  29. REMOVE COOLING UNIT CASE SUB-ASSEMBLY (w/o Air Conditioning System)


    1. A004I6Z

      Remove the 7 screws.

    2. Disengage the 2 claws and remove the cooling unit case sub-assembly.

  30. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A004ICP

      Remove the No. 1 cooler evaporator sub-assembly with evaporator pipe as a unit.

  31. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  32. REMOVE COVER PLATE (w/o Air Conditioning System)


    1. Remove the cover plate.

  33. REMOVE NO. 1 COOLER THERMISTOR (for Automatic Air Conditioning System)


    1. A004IFM

      Remove the No. 1 cooler thermistor.

  34. REMOVE NO. 1 COOLER THERMISTOR (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  35. REMOVE AIR CONDITIONER TUBE ASSEMBLY (for Automatic Air Conditioning System)


    1. A004KQX

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

  36. REMOVE AIR CONDITIONER TUBE ASSEMBLY (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  37. REMOVE BLOWER MOTOR CONTROL (for Automatic Air Conditioning System)


    1. A004ICA

      Remove the 2 screws and remove the blower motor control.

  38. REMOVE BLOWER RESISTOR (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  39. REMOVE BLOWER RESISTOR (w/o Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  40. REMOVE COOLER BLOWER CASE


    1. A004JTY

      Remove the 4 screws and disengage the 2 claws.

    2. Remove the cooler blower case from the lower heater case.

  41. REMOVE COOLER UNIT CASE PACKING (for Automatic Air Conditioning System)


    1. A004IT9

      Remove the cooler unit case packing.

  42. REMOVE COOLER UNIT CASE PACKING (for Manual Air Conditioning System)

    Tech Tips

    Use the same procedure as for the automatic air conditioning system.

  43. REMOVE COVER PLATE


    1. A004KXU

      Remove the cover plate.