Disassembly

HEATING / AIR CONDITIONING: FRONT AIR CONDITIONING UNIT: DISASSEMBLY

1. REMOVE BLOWER ASSEMBLY Removal







2. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.






3. REMOVE NO. 5 AIR DUCT SUB-ASSEMBLY
(a) Remove the screw and duct.






4. REMOVE ASPIRATOR
(a) Detach the 2 claws and remove the aspirator.
5. REMOVE COOL BOX LIQUID TUBE (w/ Cool Box)





(a) Detach the clamp.
(b) Using SST, remove the piping clamp.
SST: 09870-00025





(1) Attach SST to the piping clamp.
HINT:
Confirm the direction of the piping clamp claw and SST by referring to the illustration on the caution label.





(2) Push down SST and release the clamp lock.
NOTICE:
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.
(c) Disconnect the tube.
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.

(d) Remove the 2 O-rings from the liquid tube.






6. REMOVE QUICK HEATER ASSEMBLY (w/ PTC Heater)
(a) Detach the 3 clamps.
(b) Remove the 2 screws and quick heater.
7. REMOVE AIR CONDITIONER HARNESS





(a) Disconnect the connectors.
(b) Detach the clamps and remove the harness.






8. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY
(a) Remove the screw and radiator bracket.
(b) Remove the radiator.
9. REMOVE COOLER EXPANSION VALVE (w/ Cool Box)





(a) Remove the packing.






(b) Remove the butyl tape.






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






(d) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and No. 1 connector tube.
(e) Remove the 2 O-rings from the No. 1 connector tube.






(f) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts, No. 2 connector tube, expansion valve and No. 3 connector tube.
(g) Remove the 2 O-rings from the No. 2 connector tube.






10. REMOVE AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Cool Box)
(a) Remove the screw and bracket.
(b) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and air conditioner tube and accessory assembly.
(c) Remove the 2 O-rings from the air conditioner tube and accessory assembly.
11. REMOVE COOLER EXPANSION VALVE (w/o Cool Box)





(a) Remove the packing.






(b) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts, air conditioner tube and accessory assembly and expansion valve.
(c) Remove the 2 O-rings from the air conditioner tube and accessory assembly.
(d) Remove the 2 O-rings from the expansion valve.






12. REMOVE REAR AIR MIX DAMPER CONTROL SERVO MOTOR RH
(a) Remove the 3 screws and servo motor.
13. REMOVE SERVO MOTOR





(a) Remove the 4 screws and servo motor unit.






(b) Remove the front mode control servo motor RH.
(1) Remove the 2 screws.
(2) Detach the claw and remove the plate and servo motor.
NOTICE:
Be careful not to damage the claw of the plate.





(c) Remove the control air bypass damper control servo motor.
(1) Remove the 2 screws.
(2) Detach the claw and remove the plate and servo motor.
NOTICE:
Be careful not to damage the claw of the plate.





(d) 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.
NOTICE:
Be careful not to damage the claw of the plate.

14. REMOVE SERVO MOTOR





(a) Remove the 4 screws and servo motor unit.






(b) Detach the 3 claws and remove the plate.
NOTICE:
Be careful not to damage the claw of the plate.





(c) Remove the front mode control servo motor LH.
(1) Remove the 2 screws.
(2) Detach the claw and remove the plate and servo motor.
NOTICE:
Be careful not to damage the claw of the plate.





(d) 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.
NOTICE:
Be careful not to damage the claw of the plate.

15. REMOVE SERVO MOTOR





(a) Remove the 3 screws and servo motor unit.






(b) Remove the rear mode control servo motor.
(1) Remove the 2 screws.
(2) Detach the claw and remove the plate and servo motor.
NOTICE:
Be careful not to damage the claw of the plate.





(c) Remove the rear air mix damper control servo motor RH.
(1) Remove the 2 screws.
(2) Detach the claw and remove the lever and servo motor.
NOTICE:
Be careful not to damage the claw of the lever.

16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY
(a) Remove the 7 screws.
(b) Detach the 6 claws and remove the unit case.
(c) Remove the evaporator.









17. REMOVE FRONT EVAPORATOR TEMPERATURE SENSOR
(a) Remove the sensor from the evaporator.