DISASSEMBLY

PROCEDURE

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

(a) Disconnect the 2 connectors.

(b) Disengage the 5 clamps to remove the No. 3 instrument panel wire.

2. REMOVE NO. 2 AIR DUCT

(a) Remove the screw.

*a	View A
	Front

(b) Disengage the 3 claws to remove the No. 2 air duct.

NOTICE:

Be careful not to deform or damage the lower heater case of the air conditioner unit assembly when removing the No. 2 air duct.

3. REMOVE BLOWER ASSEMBLY

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4. REMOVE GROMMET (for Manual Air Conditioning System)

(a) Disengage the 2 claws to remove the grommet.

5. REMOVE ASPIRATOR (for Automatic Air Conditioning System)

(a) Disengage the guide and 2 claws to remove the aspirator.

6. REMOVE COVER (w/ Cover)

(a) Disengage the 3 claws to remove the cover.

7. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct)

(a) Disengage the 3 claws and remove the rear No. 1 air duct as shown in the illustration.

Remove in this Direction

8. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

(a) Disconnect the connector.

Remove in this Direction

(b) Remove the screw.

(c) Disengage the guide to remove the air conditioning amplifier assembly as shown in the illustration.

9. REMOVE AIR CONDITIONING HARNESS ASSEMBLY

(a) Disconnect each connector.

*A w/ PTC Heater *B for 3 Zone Type *C for 3 Zone Type or with PTC Heater

(b) Disengage each clamp to remove the air conditioning harness assembly.

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

(a) Remove the screw and heater cover as shown in the illustration.

Remove in this Direction

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

(a) Remove the screw.

(b) Disengage the claw and 2 guides to remove the No. 2 heater cover.

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

(a) Remove the quick heater assembly as shown in the illustration.

Remove in this Direction

13. REMOVE DRAIN COOLER HOSE

(a) Remove the drain cooler hose.

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

(a) for Single Type:

(1) Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.

(b) for Dual Type:

(1) Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.

15. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (w/ PTC Heater)

(a) Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

16. REMOVE NO. 3 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for 3 Zone Type)

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

17. REMOVE HEATER GROMMET

(a) Remove the heater grommet.

18. REMOVE HEATER CLAMP

(a) Disengage the 3 claws to remove the heater clamp.

19. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY

Remove in this Direction

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

NOTICE:

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

20. REMOVE COOLING UNIT PARTS

(a) Remove the cooling unit parts.

21. REMOVE COOLER EXPANSION VALVE

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

(b) Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

22. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

(a) Remove the 2 screws.

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

(c) Disengage the clamp.

(d) for HFC-134a (R134a):

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

(e) for HFO-1234yf (R1234yf):

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

NOTICE:

When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

23. REMOVE NO. 1 COOLER THERMISTOR

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