Disassembly

AIR CONDITIONING: FRONT COOLING UNIT: DISASSEMBLY

1. REMOVE TRANSPONDER KEY ECU (w/o Smart Key System) Removal

2. REMOVE ID CODE BOX (IMMOBILISER CODE ECU) (w/ Smart Key System) Removal

3. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY

(a) Disengage the 3 claws and remove the No. 3 air duct sub-assembly as shown in the illustration.

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

(a) Remove the 3 screws.

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

5. REMOVE BLOWER ASSEMBLY (for TMC Made)

(a) Disconnect the connector.

(b) Remove the 2 screws.

(c) Disengage the 2 claws and remove the blower assembly.

6. REMOVE FRONT AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY (for TMC Made)

(a) Disconnect the 2 connectors.

(b) Remove the 3 screws and the front air outlet control servo motor sub-assembly.

7. REMOVE FRONT AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY (for TMC Made)

(a) for Automatic Air Conditioning System:

(1) Disconnect the connector.

(2) Remove the 2 screws and front air mix control servo motor sub-assembly.

8. REMOVE HEATER CLAMP (for TMC Made)

(a) Remove the screw and the clamp.

(b) Disengage the 3 claws and remove the heater clamp.

9. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (for TMC Made)

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

NOTICE:
Prepare a drain pan or cloth in case the cooling water leaks.

10. REMOVE ASPIRATOR (for TMC Made)

(a) for Manual Air Conditioning System:

(1) Disengage the 2 claws and remove the aspirator.

(b) for Automatic Air Conditioning System:

(1) Disengage the clamp.

(2) Disengage the 2 claws and remove the aspirator.

11. REMOVE COOLER EXPANSION VALVE (for TMC Made)

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

12. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (for TMC Made)

(a) Disconnect the connector.

(b) Remove the 6 screws.

(c) Disengage the 5 claws and remove the plate cover.

(d) Disengage the clamp and remove the No. 1 cooler evaporator sub-assembly with the No. 1 cooler thermistor.

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

(f) Disengage the 4 claws to remove the evaporator insulator.

13. REMOVE NO. 1 COOLER THERMISTOR (for TMC Made)

(a) Remove the No. 1 cooler thermistor.

14. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY (except TMC Made)

(a) Disconnect each connector and disengage the air conditioning harness assembly.

(b) Remove the 6 screws and air conditioning radiator assembly from the blower assembly with evaporator sub-assembly.

15. REMOVE COOLER EXPANSION VALVE (except TMC Made)

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

16. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (except TMC Made)

(a) Disengage the clamp and remove the No. 1 cooler evaporator sub-assembly with the No. 1 cooler thermistor.

(b) Remove the 2 O-rings from the evaporator sub-assembly.

17. REMOVE NO. 1 COOLER THERMISTOR (except TMC Made)

(a) Remove the No. 1 cooler thermistor.

18. REMOVE ASPIRATOR (except TMC Made)

(a) for Manual Air Conditioning System:

(1) Disengage the 2 claws and remove the aspirator pipe.

(b) for Automatic Air Conditioning System:

(1) Disengage the clamp.

(2) Disengage the 2 claws and remove the aspirator pipe.

19. REMOVE FRONT AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY (except TMC Made)

(a) for Automatic Air Conditioning System:

(1) Remove the 2 screws and front air mix control servo motor sub-assembly.

20. REMOVE FRONT AIR OUTLET CONTROL SERVO MOTOR SUB-ASSEMBLY (except TMC Made)

(a) Remove the 3 screws and air outlet control servo motor sub-assembly.

21. REMOVE HEATER CLAMP (except TMC Made)

(a) Remove the screw and clamp.

(b) Disengage the 3 claws and remove the heater clamp.

22. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (except TMC Made)

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

NOTICE:
Prepare a drain pan or cloth in case the cooling water leaks.