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Home >> Subaru >> 2016 >> BRZ Series.HyperBlue >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> HVAC System (Heater, Ventilator And A/C) >> Air Conditioner Radiator Assembly >> Disassembly

Air Conditioner Radiator Assembly: Disassembly

  1. Removal of aspirator (for automatic air conditioning system)
    1. Release the 2 claws and remove the aspirator.
      Fig 1: Locating Aspirator Claws
      G08553512Courtesy of SUBARU OF AMERICA, INC.
  2. Removal of air conditioner radiator damper servo sub-assembly No. 1
    1. Remove the 2 screws and remove the air conditioner radiator damper servo sub-assembly No. 1.
      Fig 2: Locating Air Conditioner Radiator Damper Servo Sub-Assembly No. 1 Screws
      G08553513Courtesy of SUBARU OF AMERICA, INC.
  3. Removal of air conditioner radiator damper servo sub-assembly No. 5 (for automatic air conditioning system)
    1. Remove the 2 screws and remove air conditioner radiator damper servo sub-assembly No. 5.
      CAUTION: When reusing air conditioner radiator damper servo sub-assembly No. 5, set the controller position to MAXCOOL on the vehicle before removal and hold it for 30 seconds after setting.
      Fig 3: Locating Air Conditioner Radiator Damper Servo Sub-Assembly No. 5 Screws
      G08553514Courtesy of SUBARU OF AMERICA, INC.
  4. Removal of heater cover (for automatic air conditioning system)
    1. Remove the 3 screws and remove the heater cover.
      Fig 4: Locating Heater Cover Screws
      G10217109Courtesy of SUBARU OF AMERICA, INC.
  5. Removal of heater cover (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  6. Removal of heater radiator unit sub-assembly (for automatic air conditioning system)
    1. Remove the screw and remove the clamp.
      Fig 5: Locating Heater Radiator Unit Sub-Assembly Screw
      G08553516Courtesy of SUBARU OF AMERICA, INC.
    2. Slide the heater radiator unit sub-assembly in the direction of the arrow in the figure to remove it.
      Fig 6: Sliding Heater Radiator Unit Sub-Assembly
      G10217111Courtesy of SUBARU OF AMERICA, INC.
  7. Removal of heater radiator unit sub-assembly (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  8. Removal of air filter case
    1. Release the 2 claws and remove the air filter case.
      Fig 7: Identifying Air Filter Case Claws
      G10217112Courtesy of SUBARU OF AMERICA, INC.
  9. Removal of clean air filter
    1. Slide the clean air filter in the direction of the arrow in the figure to remove it.
      Fig 8: Removing Clean Air Filter
      G10217113Courtesy of SUBARU OF AMERICA, INC.
  10. Removal of cooling unit case
    1. Remove the 2 screws.
    2. Release the 4 claws and remove the cooling unit case.
      Fig 9: Locating Cooling Unit Case Claws And Screws
      G10217114Courtesy of SUBARU OF AMERICA, INC.
  11. Removal of cooler expansion valve (for automatic air conditioning system)
    1. Remove the gasket.
      Fig 10: Locating Cooler Expansion Valve And Gasket
      G10217115Courtesy of SUBARU OF AMERICA, INC.
    2. Using hexagon socket wrench 4, remove the 2 hexagon bolts and the cooler expansion valve.
      Fig 11: Locating Hexagon Bolts And Cooler Expansion Valve
      G10217116Courtesy of SUBARU OF AMERICA, INC.
    3. Remove the 2 O-rings from cooler evaporator No. 1.
      Fig 12: Locating O-Rings From Cooler Evaporator No. 1
      G08553523Courtesy of SUBARU OF AMERICA, INC.
  12. Removal of cooler expansion valve (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  13. Removal of cover
    1. Remove the 3 screws.
    2. Release the 2 claws and remove the cover.
      Fig 13: Locating Cover Screws And Claws
      G10217118Courtesy of SUBARU OF AMERICA, INC.
  14. Removal of cooler unit drain hose No. 1
    1. Remove cooler unit drain hose No. 1.
      Fig 14: Removing Cooler Unit Drain Hose No. 1
      G08553525Courtesy of SUBARU OF AMERICA, INC.
  15. Removal of air duct No. 1
    1. Remove the 2 screws and remove air duct No. 1.
      Fig 15: Locating Air Duct No. 1 Screws
      G10217120Courtesy of SUBARU OF AMERICA, INC.
  16. Removal of blower motor sub-assembly (with fan)
    1. Remove the 3 screws and remove the blower motor sub-assembly (with fan).
      Fig 16: Locating Blower Motor Sub-Assembly Screws
      G10217121Courtesy of SUBARU OF AMERICA, INC.
  17. Removal of air duct No. 2
    1. Remove the 3 screws and remove air duct No. 2.
      Fig 17: Locating Air Duct No. 2 Screws
      G10217122Courtesy of SUBARU OF AMERICA, INC.
  18. Removal of air conditioner radiator damper servo sub-assembly No. 4 (for automatic air conditioning system)
    1. Remove the 2 screws and remove air conditioner radiator damper servo sub-assembly No. 4.
      CAUTION: When reusing air conditioner radiator damper servo sub-assembly No. 4, set the controller position to the servo motor opening angle 32.42 % on the vehicle before removal and hold it for 30 seconds after setting.
      Fig 18: Locating Air Conditioner Radiator Damper Servo Sub-Assembly No. 4 Screws
      G08553529Courtesy of SUBARU OF AMERICA, INC.
  19. Removal of air conditioner radiator damper servo sub-assembly No. 3 (for automatic air conditioning system)
    1. Remove the 3 screws and remove air conditioner radiator damper servo sub-assembly No. 3.
      Fig 19: Locating Air Conditioner Radiator Damper Servo Sub-Assembly No. 3 Screws
      G08553530Courtesy of SUBARU OF AMERICA, INC.
  20. Removal of air outlet damper control cable sub-assembly (for manual air conditioning system)
    1. Release the 3 claws and remove the air outlet damper control cable sub-assembly.
      CAUTION: Hold the control cable and remove it slowly so that the drive gear at the unit may not be pulled.
      Fig 20: Locating Air Outlet Damper Control Cable Sub-Assembly Claws
      G10217125Courtesy of SUBARU OF AMERICA, INC.
  21. Removal of heater control cable sub-assembly (for manual air conditioning system)
    1. Release the 3 claws and remove the heater control cable sub-assembly.
      CAUTION: Hold the control cable and remove it slowly so that the drive gear at the unit may not be pulled.
      Fig 21: Locating Heater Control Cable Sub-Assembly Claws
      G10217126Courtesy of SUBARU OF AMERICA, INC.
  22. Removal of cooling unit case (for automatic air conditioning system)
    1. Disconnect the clamp.
      Fig 22: Locating Cooling Unit Case Clamp
      G10217127Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the 7 screws.
    3. Release the 2 claws and remove the cooling unit case.
      Fig 23: Locating Cooling Unit Case Screws And Claws
      G10217128Courtesy of SUBARU OF AMERICA, INC.
  23. Removal of cooling unit case (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  24. Removal of cooler evaporator No. 1 (for automatic air conditioning system)
    1. Remove cooler evaporator No. 1.
      Fig 24: Identifying Cooler Evaporator No. 1
      G10217129Courtesy of SUBARU OF AMERICA, INC.
  25. Removal of cooler evaporator No. 1 (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  26. Removal of cooler thermistor No. 1 (for automatic air conditioning system)
    1. Remove the cooler thermistor No. 1.
      Fig 25: Removing Cooler Thermistor No. 1
      G10217130Courtesy of SUBARU OF AMERICA, INC.
  27. Removal of cooler thermistor No. 1 (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  28. Removal of air conditioner tube assembly (for automatic air conditioning system)
    1. Using hexagon socket wrench 4, remove the 2 hexagon bolts and the air conditioner tube assembly.
      Fig 26: Locating Hexagon Bolts And Air Conditioner Tube Assembly
      G10217131Courtesy of SUBARU OF AMERICA, INC.
  29. Removal of air conditioner tube assembly (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  30. Removal of blower motor control (for automatic air conditioning system)
    1. Remove the 2 screws and remove the blower motor control.
      Fig 27: Locating Blower Motor Control Screws
      G10217132Courtesy of SUBARU OF AMERICA, INC.
  31. Removal of blower register (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the blower motor control.
  32. Removal of cooler blower case
    1. Remove the 4 screws and release the 2 claws.
      Fig 28: Locating Cooler Blower Case Screws And Claws
      G10217133Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the cooler blower case from the heater case lower.
      Fig 29: Removing Cooler Blower Case From Heater Case Lower
      G08553540Courtesy of SUBARU OF AMERICA, INC.
  33. Removal of cooler unit case gasket (for automatic air conditioning system)
    1. Remove the cooler unit spacer.
      Fig 30: Identifying Cooler Unit Spacer
      G10217135Courtesy of SUBARU OF AMERICA, INC.
  34. Removal of cooler unit case gasket (for manual air conditioning system)
    NOTE: Repeat the same removal steps for the automatic air conditioning system.
  35. Removal of cover plate
    1. Remove the cover plate.
      Fig 31: Identifying Cover Plate
      G10217136Courtesy of SUBARU OF AMERICA, INC.
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