Disassembly

AIR CONDITIONING UNIT:

DISASSEMBLY

1. REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER

(a) Remove the 4 bolts and the defroster nozzle assembly lower.
2. REMOVE HEATER TO REGISTER CENTER DUCT

(a) Remove the 2 bolts and heater to register duct center.
3. REMOVE NO. 1 AIR DUCT

(a) Remove the bolt.
(b) Disengage the 3 claws and remove the air duct.
4. REMOVE AIR FILTER

(a) Push down on the 2 tabs and open the filter door.
(b) Remove the air filter.
5. REMOVE MODE CONTROL SERVO MOTOR

(a) Remove the 3 bolts and mode control servo motor.
6. REMOVE AIR MIX CONTROL SERVO MOTOR

(a) Remove the 2 bolts and air mix control servo motor.
7. REMOVE AIR INLET CONTROL SERVO MOTOR

(a) Remove the 2 bolts and air inlet control servo motor.
8. REMOVE HEATER RADIATOR ASSEMBLY

(a) Remove the 3 bolts and temperature mounting plate.

(b) Remove the temperature cam.

(d) Using "Torx" socket wrench T30, remove the bolt, clamp and heater radiator assembly.
9. REMOVE BLOWER RESISTOR

(a) Remove the 2 bolts and blower resistor.
10. REMOVE BLOWER MOTOR

(a) Remove the 3 bolts and blower motor.
11. REMOVE EVAPORATOR CORE

(a) Remove the 3 bolts and mode mounting plate.

(b) Remove the mode cam.

(d) Disengage the clip and remove the 11 bolts and mode case.

(e) Remove the evaporator core.

HINT: If a new evaporator is installed, add compressor oil to the evaporator as follows.

Compressor oil:
RL-897 or equivalent
Add 40 cc (1.4 fl.oz.)
12. REMOVE VALVE TO CONNECTOR TUBE

(a) Using "Torx" socket wrench E10, remove the bolt and valve to connector tube.
(b) Remove the 2 seal washers from the air conditioning tube assembly.
13. REMOVE EXPANSION VALVE

(a) Using "Torx" socket wrench T25, remove the 2 bolts and expansion valve.
(b) Remove the 2 seal washers from the expansion valve.
14. REMOVE COOLER THERMISTOR SENSOR

(a) Disengage the 2 clamps and remove the cooler thermistor sensor.
15. REMOVE NO. 1 COOLER UNIT DRAIN HOSE