AIR CONDITIONING UNIT REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE WINDSHIELD WIPER ARM COVER


    1. Remove the 2 windshield wiper arm covers.

  3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Remove the nut and front wiper arm and blade assembly RH.

  4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. Remove the nut and front wiper arm and blade assembly LH.

  5. REMOVE COWL VENT COVER RH


    1. A01BAKI

      Disengage the 2 claws and remove the cowl vent cover RH as shown in the illustration.

  6. REMOVE COWL VENT COVER LH


    1. A01BFTQ

      Disengage the 2 claws and remove the cowl vent cover LH as shown in the illustration.

  7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01BCN5E01

      Disconnect the washer hose at position <a> shown in the illustration.

    2. Body type narrow:


      1. Disengage the 10 claws, and remove the 6 clips and cowl top ventilator louver sub-assembly.

    3. Body type wide:


      1. Disengage the 11 claws, and remove the 7 clips and cowl top ventilator louver sub-assembly.

  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01BB0PE01

      Disconnect the connector.

    2. Remove the 2 bolts.

    3. Disengage the grommet and remove the windshield wiper motor and link assembly as shown in the illustration.

  9. REMOVE ENGINE UNDER COVER NO.1 (w/ Under Cover and Intercooler)

  10. DRAIN ENGINE COOLANT (w/ Intercooler)

  11. REMOVE RADIATOR GRILLE (for Standard Body)

    A01BEGKE01
    Text in Illustration
    *1 Protective Tape

    1. Put protective tape around the radiator grille.

    2. Remove the 4 clips and 2 screws.

    3. Detach the 6 claws and 2 clips and remove the radiator grille.

  12. REMOVE RADIATOR GRILLE (for Wide Body)

    A01BC6JE01
    Text in Illustration
    *1 Protective Tape

    1. Put protective tape around the radiator grille.

    2. Remove the 4 clips and 2 screws.

    3. Detach the 6 claws and 2 clips and remove the radiator grille.

  13. REMOVE AIR INLET DUCT (w/ Intercooler)


    1. A01BDSHE01

      Remove the 3 clips and the air inlet duct No.2.

    2. Remove the 2 bolts, 2 clips and the air inlet duct No.1.

  14. DRAIN WINDSHIELD WASHER FLUID (w/ Intercooler)

  15. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (w/o Rear Wiper and w/ Intercooler)


    1. A01BD06

      Remove the 2 bolts.

    2. Separate the hose and connector, and remove the windshield washer jar assembly.

  16. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (w/ Rear Wiper and Intercooler)


    1. A01BD06

      Remove the 2 bolts.

    2. Separate the 2 hoses and 2 connectors, and remove the windshield washer jar assembly.

  17. REMOVE RADIATOR RESERVE TANK ASSEMBLY (w/ Intercooler)


    1. A01BHM3

      Remove the bolt, and separate the radiator reserve tank assembly from the body panel.

    2. Remove the clip, and disconnect the water by-pass hose No.1.

    3. Remove the clip, and disconnect the water by-pass hose No.2.

    4. Remove the radiator reserve tank assembly.

  18. REMOVE HOOD LOCK ASSEMBLY (w/ Intercooler)


    1. A01BBWB

      Remove the 3 bolts, hood lock control cable and the hood lock assembly.

  19. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY (w/ Intercooler)


    1. A01BFVV

      Remove the 6 bolts, 2 screws and the radiator upper support.

  20. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. A01BA8AE01

      Loosen the clamp, and disconnect the air hose No.2.

    2. Loosen the clamp, and disconnect the air hose No.3.

    3. Remove the 3 bolts and the intercooler assembly.

  21. DISCONNECT COOLER REFRIGERANT SUCTION PIPE A


    1. A01BEZFE01

      Remove the bolt, and slide the hook connector.

    2. Disconnect the cooler refrigerant suction pipe A.

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

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  22. DISCONNECT COOLER REFRIGERANT LIQUID PIPE B


    1. Disconnect the cooler refrigerant liquid pipe B.

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

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  23. DISCONNECT HEATER WATER HOSE OUTLET


    1. A01BHCKE01

      Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.

  24. DISCONNECT HEATER WATER HOSE INLET A

    Tech Tips

    Disconnection of the heater water outlet hose A is the same as for the heater water inlet hose A.

  25. REMOVE INSTRUMENT PANEL ASSEMBLY

    Tech Tips

    Refer to the instruction for removal of the instrument panel assembly. Click here

  26. REMOVE STEERING INTERMEDIATE SHAFT


    1. Remove the steering intermediate shaft Click here.

  27. REMOVE STEERING COLUMN ASSEMBLY


    1. Remove the steering column assembly Click here.

  28. REMOVE AIR DUCT NO.1


    1. A01BDNAE01

      Remove the clip.

    2. Release the 2 claws and remove the air duct No.1.

  29. DISCONNECT PARKING BRAKE CONTROL HANDLE SUB-ASSEMBLY


    1. A01BHK6

      Remove the 2 bolts and disconnect the parking brake control handle sub-assembly.

  30. REMOVE INSTRUMENT PANEL TO FLOOR BRACE SUB-ASSEMBLY


    1. A01BF19

      Remove the 5 bolts and the instrument panel to floor brace sub-assembly.

  31. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Remove the clamps and connectors, and then disconnect the wire harness.

      A01BBEIE01

    2. Remove the bolts, nuts and junction blocks.

    3. Remove the 2 caps and 2 bolts.

      A01BEABE01

    4. Remove the 2 bolts and nut. (AUTOMATIC TRANSMISSION)

    5. Remove the 3bolts and nut. (MANUAL TRANSMISSION)

    6. Using a "Torx" socket wrench (T40), remove the 4 "Torx" bolts.

      Tech Tips

      The "Torx" bolts on the passenger side can be removed with the collar for adjustment.

    7. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly.

  32. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Remove the 3 bolts and air conditioner unit assembly.

      A01BHGU

  33. REMOVE AIR DUCT NO.2


    1. A01BGCOE01

      Release the 2 claws and remove the air duct No.2.

  34. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. A01BFB9

      w/ PTC


      1. Remove the screw and then disconnect the wire harness.

    2. A01BFMG

      Remove the 3 screws and air conditioning radiator assembly.