Toyota CH-R Service Manual: Disassembly

DISASSEMBLY

PROCEDURE

1. PRECAUTION

NOTICE:

Make sure to perform initialization after replacing the air conditioning radiator damper servo sub-assembly. If initialization is not performed, the air conditioner unit assembly will not perform properly as the air conditioning amplifier assembly will not be able to recognize the position of the air conditioning radiator damper sub-assembly.

2. REMOVE ID CODE BOX (IMMOBILISER CODE ECU)

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3. REMOVE NO. 2 AIR DUCT

(a) Remove the screw.

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(b) Disengage the claws to remove the No. 2 air duct as shown in the illustration.

4. REMOVE AIR CONDITIONING DUCT SUB-ASSEMBLY

(a) Disengage the guide to remove the air conditioning duct sub-assembly.

5. REMOVE COVER (except Cold Area Specification Vehicles)

(a) Disengage the claws to remove the cover.

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

(a) Disconnect the connector.

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

7. REMOVE NO. 3 COOLER UNIT DRAIN HOSE

(a) Remove the No. 3 cooler unit drain hose.

8. REMOVE BLOWER ASSEMBLY

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

(a) Remove the 2 screws and heater cover as shown in the illustration.

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

(a) Remove the screw and No. 2 heater cover.

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

(a) Remove the 2 screws and quick heater assembly as shown in the illustration.

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12. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

(a) Disconnect the connector.

(b) Remove the screw.

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

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	Remove in this Direction (2)

13. REMOVE AIR CONDITIONING HARNESS ASSEMBLY

(a) Disconnect the 5 connectors.

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

14. REMOVE DRAIN COOLER HOSE

(a) Remove the drain cooler hose.

15. REMOVE NO. 2 COOLER UNIT DRAIN HOSE

(a) Remove the No. 2 cooler unit drain hose.

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

(a) for Upper LH Side:

(1) Turn the No. 1 air conditioning radiator damper servo sub-assembly to disengage the claw as shown in the illustration.

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(2) Remove the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

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(b) for Lower LH Side:

(1) Disengage the snap.

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(2) Turn the No. 1 air conditioning radiator damper servo sub-assembly to disengage the claw as shown in the illustration.

(3) Remove the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

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(c) for Upper RH Side:

(1) Turn the No. 1 air conditioning radiator damper servo sub-assembly to disengage the claw.

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(2) Remove the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

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(d) for Lower RH Side:

(1) Disengage the snap.

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(2) Turn the No. 1 air conditioning radiator damper servo sub-assembly to disengage the claw as shown in the illustration.

(3) Remove the No. 1 air conditioning radiator damper servo sub-assembly as shown in the illustration.

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17. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY

(a) Turn the No. 2 air conditioning radiator damper servo sub-assembly to disengage the claw as shown in the illustration.

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(b) Remove the No. 2 air conditioning radiator damper servo sub-assembly as shown in the illustration.

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18. REMOVE HEATER PIPE GROMMET

(a) Remove the heater pipe grommet.

19. REMOVE HEATER CLAMP

(a) Remove the screw.

(b) Disengage the claws to remove the heater clamp.

20. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY

(a) Remove the 3 screws.

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

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NOTICE:

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

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.

(c) Remove the grommet.

22. REMOVE HEAT EXCHANGER CASE

(a) Remove the 2 screws and the bracket.

(b) Disengage the claws and guide, and remove the screw to remove the heat exchanger case.

23. REMOVE RADIATOR CASE SUB-ASSEMBLY

(a) Remove the 3 screws.

(b) Disengage the claws to remove the radiator case sub-assembly.

24. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY

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(a) Disconnect the connector.

(b) Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor as shown in the illustration.

25. REMOVE NO. 2 RADIATOR CASE SUB-ASSEMBLY

(a) Remove the 6 screws and the No. 2 radiator case sub-assembly.

26. REMOVE NO. 1 COOLER THERMISTOR

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