PTC HEATER ASSEMBLY REMOVAL


  1. DRAIN ENGINE COOLANT (for 1KD-FTV)

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  2. DRAIN ENGINE COOLANT (for 2KD-FTV)

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.


    1. Remove the radiator cap.

    2. A01KIHQE01
      Text in Illustration
      *1 Engine Drain Plug
      *2 Radiator Drain Plug

      Loosen the radiator drain plug (on the right side of the radiator lower tank) and engine drain plug (on the oil cooler cover), and drain the coolant.

    3. Close the drain plugs.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE RADIATOR GRILLE


    1. A01KICYE01
      Text in Illustration
      *a Clip

      Remove the screw and 9 clips and radiator grille.

  5. DISCONNECT HEATER WATER HOSE INLET B

    A01KF0N

    1. Remove the bolt and remove the heater bracket.

    2. A01KHQZ

      Slide the clip and disconnect the heater water inlet hose.

  6. DISCONNECT HEATER WATER HOSE OUTLET B


    1. Slide the clip and disconnect the heater water inlet hose.

  7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY


    1. Remove the 2 clips.

    2. Remove the 2 nuts<F> and 7 bolts<A><B>.

    3. Disconnect the connectors and remove the instrument panel sub-assembly.

      A01KFKFE02
      Text in Illustration
      *a Pin *b 4 Pins

  8. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

    A01KH25

    1. Remove the bolt and disconnect the brake master cylinder reservoir.

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

    A01KIKT

    1. Remove the 2 bolts, nut and remove the instrument panel brace.

  10. REMOVE FRONT DOOR SCUFF PLATE RH

  11. REMOVE STEERING COLUMN UPPER COVER

    A01KFDF

    1. Remove the 2 screws and steering column cover UPR.

  12. REMOVE STEERING COLUMN LOWER COVER

    A01KHSI

    1. Remove the clip, 2 screws and steering column cover LWR.

  13. REMOVE NO. 2 AIR DUCT (for LHD)

    A01KEUL

    1. Remove the 2 clips and remove the air duct (for Cold Area Specification Vehicles).

    2. A01KHSM

      Remove the clip and remove the air duct (except Cold Area Specification Vehicles).

  14. REMOVE NO. 1 AIR DUCT

    A01KGD5

    1. Remove the 2 clips and the air duct.

  15. SEPARATE STEERING COLUMN ASSEMBLY

    A01KGWE

    1. Remove the 2 bolts and clamp bracket.

    2. A01KGTVE01
      Text in Illustration
      *A Non-Tilt Column Assembly
      *B Tilt Column Assembly

      Remove the 4 steering column assembly set bolts and steering column assembly.

  16. SEPARATE STEERING COLUMN LOWER TUBE ASSEMBLY

    A01KENP

    1. Remove the 4 bolts and separate steering column tube.

  17. REMOVE INSTRUMENT PANEL REINFORCEMENT

    A01KGFG

    1. Remove the 2 bolts, 4 nuts and remove the instrument panel reinforcement.

  18. REMOVE WINDSHIELD WASHER JAR ASSEMBLY

    A01KFM9

    1. Remove the 2 bolts and the windshield washer jar.

    2. A01KFSD

      Disconnect the hose and connector from the washer pump.

  19. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY

    A01KHYO

    1. Remove the 3 bolts and disconnect the relay block.

    2. A01KI33

      Remove the screw and disconnect the relay block.

    3. A01KH6U

      Remove the bolt.

    4. Disconnect the blower resistor connector.

    5. A01KGO4

      Disconnect the relay block.

    6. A01KFLG

      Remove the 2 bolts, 4 screws and the air duct.

  20. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY

    A01KG8P

    1. Remove the screw and remove the lower defroster nozzle.

  21. SEPARATE SKID CONTROL ECU ASSEMBLY

    A01KFOM

    1. Remove the 2 screws and separate the skid control ECU.

  22. SEPARATE ECM (for 1KD-FTV, 2KD-FTV)

    A01KHA8

    1. Remove the 4 screws and separate the ECM.

  23. REMOVE HEATER RADIATOR ASSEMBLY

    A01KG7G

    1. Disengage the 2 claws and disconnect the connector.

    2. A01KEEJ

      Disconnect the outer cable from the clamp.

    3. A01KFSO

      Remove the 4 nuts and the heater radiator.

  24. REMOVE HEATER CONTROL CABLE SUB-ASSEMBLY

    A01KGW0E02
    Text in Illustration
    *a Clamp

    1. Disconnect the outer cable from the clamp.

    2. Remove the inner cable.

  25. REMOVE AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY

    A01KG3XE04
    Text in Illustration
    *a Clamp

    1. Disconnect the outer cable from the clamp.

    2. Remove the inner cable.

  26. REMOVE PTC HEATER ASSEMBLY

    A01KEIA

    1. Remove the 3 screws and remove the PTC heater.