AIR CONDITIONING UNIT REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. A/C switch on.

    3. Turn the blower switch to on.

    4. Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the remaining compressor oil from each component, in the cooler compressor.

    5. Stop the engine.

    6. Remove the caps from the service valves on the refrigerant line.

      A01CJ5AE01
      Text in Illustration
      *1 High Pressure Service Valve *2 Low Pressure Service Valve

    7. Connect the refrigerant recovery unit.

    8. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

      Tech Tips

      Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

  2. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly, radiator drain cock plug or engine drain plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CGQLE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly
      *2 Radiator Drain Cock Plug
      *3 Engine Drain Plug
      *4 Radiator Reservoir Assembly

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap sub-assembly, and then drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

    3. Tighten the radiator drain cock plug by hand.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  4. REMOVE HEADLIGHT ASSEMBLY RH

    Click here

  5. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY

    Click here

  6. REMOVE HEATER WATER OUTLET HOSE C

    A01CJ6K

    1. Slide the clip and disconnect the heater water outlet hose C from the air conditioning unit.

  7. REMOVE HEATER WATER INLET HOSE C

    A01CGYJ

    1. Slide the clip and disconnect the heater water inlet hose C from the air conditioning unit.

  8. SEPARATE COOLER REFRIGERANT LIQUID PIPE A

    A01CIFQ

    1. Remove the bolt and separate the cooler refrigerant liquid pipe A.

    2. Remove the O-ring from the cooler refrigerant liquid pipe A.

      Note

      Seal the opening of the disconnected parts using vinyl tape to prevent the entry of moisture and foreign matter.

  9. SEPARATE COOLER REFRIGERANT SUCTION PIPE A

    A01CJ88

    1. Remove the bolt and separate the cooler refrigerant suction pipe A.

    2. Remove the O-ring from the cooler refrigerant suction pipe A.

      Note

      Seal the opening of the disconnected parts using vinyl tape to prevent the entry of moisture and foreign matter.

  10. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  11. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  12. REMOVE ECU BRACKET


    1. Disconnect the connectors.

    2. A01CJBC

      Remove the 3 bolts and the ECU bracket.

  13. REMOVE ECU BRACKET


    1. Disconnect the connectors.

    2. A01CGZT

      Remove the 3 bolts and the ECU bracket.

  14. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY

    A01CIN4

    1. Remove the 2 clips.

    2. Detach the 2 claws and 2 guides, then remove the No. 3 air duct sub-assembly.

  15. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY

    A01CHSL

    1. Remove the 2 clips.

    2. Detach the 2 claws and remove the No. 4 air duct sub-assembly.

  16. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

    A01CHEX

    1. Remove the 3 bolts and the No. 1 instrument panel brace sub-assembly.

  17. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

    A01CJ4K

    1. Remove the bolt and separate the brake master cylinder reservoir assembly.

  18. REMOVE INSTRUMENT PANEL REINFORCEMENT


    1. Remove the bolt.

      A01CHLP

    2. Disconnect the connectors and detach the 4 clamps, then separate the wire harness.

    3. A01CJ55

      Remove the 2 grommets.

    4. Remove the 10 bolts and 2 nuts, then instrument panel reinforcement.

      A01CIRJ

  19. REMOVE NO. 1 AIR DUCT SEAL


    1. A01CIEG

      Detach the 2 clips and remove the No. 1 air duct seal.

  20. REMOVE NO. 2 AIR DUCT SEAL


    1. A01CIV6

      Detach the 2 clips and remove the No. 2 air duct seal.

  21. REMOVE AIR DAMPER CASE ASSEMBLY

    A01CH15

    1. Disconnect the connectors and detach the 4 clamps, then separate the wire harness.

    2. A01CJ8S

      Remove the 3 bolts and the air damper case assembly.

  22. REMOVE HEATER WIRE

    A01CGYQ

    1. Disconnect the connectors and detach the 3 clamps, then remove the heater wire.

  23. SEPARATE NO. 1 COOLER UNIT DRAIN HOSE

    A01CJ2K

    1. Detach the clamp.

    2. Remove the grommet and separate the No. 1 cooler unit drain hose.

  24. REMOVE AIR CONDITIONING UNIT ASSEMBLY

    A01CHA8

    1. Remove the 5 bolts and the air conditioner unit assembly.

  25. REMOVE HEATER TO REGISTER DUCT ASSEMBLY

    A01CIJ9

    1. Detach the 4 claws and remove the heater to register duct assembly.

  26. REMOVE LOWER DEFROSTER NOZZLE

    A01CGYE

    1. Detach the 4 claws and remove the lower defroster nozzle.

  27. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY

    A01CH6M

    1. Detach the 2 claws and remove the No. 2 air duct sub-assembly.

  28. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY

    A01CJ0A

    1. Detach the 2 claws and remove the No. 1 air duct sub-assembly.

  29. REMOVE NO. 1 AIR CONDITIONING AMPLIFIER ASSEMBLY

    A01CH17

    1. Remove the bolt and the No. 1 air conditioning amplifier assembly.