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HEATING / AIR CONDITIONING > AIR CONDITIONING UNIT > DISASSEMBLY

1. REMOVE ASPIRATOR (for Automatic Air Conditioning System)

a. Disengage the 2 claws and remove

the aspirator with aspirator pipe as a
unit.

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

a. Remove the aspirator pipe.

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

ASSEMBLY

a. 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)

a. Remove the 2 screws and No. 5 air

conditioning radiator damper servo

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sub-assembly.

NOTICE:
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)

a. Remove the 3 screws and heater

cover.

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

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

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

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

a. Remove the screw and the clamp.

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b. Remove the heater radiator unit sub-

assembly as shown in the illustration.

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

Conditioning System)

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

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

Conditioning System)

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

11. REMOVE AIR FILTER CASE

a. Disengage the 2 claws and remove

the air filter case.

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12. REMOVE CLEAN AIR FILTER

a. Remove the clean air filter as shown

in the illustration.

13. REMOVE COOLING UNIT CASE

a. Remove the 2 screws.

b. Disengage the 4 claws and remove

the cooling unit case.

a. Remove the gasket.

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b. Using a 4 mm hexagon socket

wrench, remove the 2 hexagon bolts
and cooler expansion valve.

c. Remove the 2 O-rings from the

evaporator pipe.

15. REMOVE COOLER EXPANSION VALVE (for Manual Air Conditioning

System)

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

16. REMOVE COVER

a. Remove the 3 screws.

b. Disengage the 2 claws and remove

the cover.

17. REMOVE NO. 1 COOLER UNIT DRAIN HOSE

a. Remove the No. 1 cooler unit drain

hose.

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18. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY

a. Remove the 2 screws and remove the

No. 1 air duct sub-assembly.

19. REMOVE BLOWER MOTOR WITH FAN SUB-ASSEMBLY

a. Remove the 3 screws and remove the

blower motor with fan sub-assembly.

20. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY

a. Remove the 3 screws and remove the

No. 2 air duct sub-assembly.

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21. REMOVE NO. 4 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-

ASSEMBLY (for Automatic Air Conditioning System)

a. Remove the 2 screws and remove the

No. 4 air conditioning radiator damper
servo sub-assembly.

NOTICE:
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)

a. 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)

a. Disengage the 3 claws and remove

the air inlet damper control cable sub-
assembly.

NOTICE:
Hold the control cable and remove
the drive gear on the unit side

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slowly, without pulling it.

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

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

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

Conditioning System)

a. Disengage the 3 claws and remove

the heater control cable sub-
assembly.

NOTICE:
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)

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

a. Disengage the clamp.

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b. Remove the 7 screws.

c. Disengage the 2 claws and remove

the cooling unit case sub-assembly.

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

Conditioning System)

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

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

System)

a. Remove the 7 screws.

b. 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)

a. Remove the No. 1 cooler evaporator

sub-assembly with evaporator pipe as
a unit.

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

Conditioning System)

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

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

a. Remove the cover plate.

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

System)

a. Remove the No. 1 cooler thermistor.

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

System)

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

35. REMOVE AIR CONDITIONER TUBE ASSEMBLY (for Automatic Air

Conditioning System)

a. Using a 4 mm hexagon socket

wrench, remove the 2 hexagon bolts
and air conditioner tube assembly.

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36. REMOVE AIR CONDITIONER TUBE ASSEMBLY (for Manual Air

Conditioning System)

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

37. REMOVE BLOWER MOTOR CONTROL (for Automatic Air Conditioning

System)

a. Remove the 2 screws and remove the

blower motor control.

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

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

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

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

40. REMOVE COOLER BLOWER CASE

a. Remove the 4 screws and disengage

the 2 claws.

b. Remove the cooler blower case from

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the lower heater case.

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

a. Remove the cooler unit case packing.

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

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

43. REMOVE COVER PLATE

a. Remove the cover plate.

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