AIR CONDITIONING UNIT (for 2WZ-TV) REMOVAL

Tech Tips

Use the same procedure for both the RH and LH sides.


  1. PRECAUTION

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  2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Switch A/C ON.

    3. Turn the blower switch to ON.

    4. Operate the cooler compressor with an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    5. Stop the engine.

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

      A01378ZE01

    7. Connect the Freon collection/recycling device to discharge the refrigerant gas remaining in the refrigeration system.

      Note

      Use the Freon collection/recycling device in accordance with the manufacturer's instruction manual.

  3. BOLTS, SCREWS AND NUTS TABLE

    Tech Tips

    All bolts, screws and nuts relevant to installing and removing the instrument panel are shown, along with their alphabetic codes, in the table below.

    A013636E01

  4. POSITION FRONT WHEELS FACING STRAIGHT AHEAD

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

  6. DRAIN ENGINE COOLANT

    Note

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


    1. A01375N

      Remove the drain plug and clip, then drain the engine coolant.

    2. Disconnect the radiator by uncoupling the radiator hose No.2.

    3. A01379O

      Remove the hose clamp, disconnect the water by-pass hose.

    4. Remove the reservoir tank cap sub-assembly.

      A01389E

  7. REMOVE FRONT WIPER ARM HEAD CAP

    A0136ST

    1. Using a screwdriver with its tip wrapped in protective tape, remove the front wiper arm head cap.

  8. REMOVE FRONT WIPER ARM LH


    1. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    2. A013933

      Remove the nut and front wiper main arm.

    3. A0135UZ

      Disengage the meshing of the secondary arm from the front wiper motor and link assembly.

      Note

      Do not bend the secondary arm when removing it.

  9. REMOVE HOOD TO COWL TOP SEAL

    A01379NE01

    1. Disengage the 8 clips and remove the hood to cowl top seal.

  10. REMOVE COWL TOP VENTILATOR LOUVER LH

    A0136Y2E01

    1. Remove the clip.

    2. Disengage the 9 claws and remove the cowl top ventilator louver LH.

    3. Disconnect the washer hose.

  11. REMOVE COWL TOP VENTILATOR LOUVER RH

    A0136GYE01

    1. Remove the clip.

    2. Disengage the 8 claws and remove the cowl top ventilator louver RH.

    3. Disconnect the washer hose.

  12. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    A0136OQ

    1. Remove the 2 bolts.

    2. Disconnect the connector and remove the front wiper motor and link assembly.

  13. REMOVE COWL TOP PANEL OUTER


    1. A0136J7

      Remove the 10 bolts and cowl top panel outer.

  14. REMOVE BATTERY


    1. Loosen the nut and disconnect the battery positive terminal.

    2. A0136EQE01

      Remove the bolt and battery clamp.

    3. Remove the battery.

  15. SEPARATE ENGINE ROOM RELAY BLOCK

    A0138XK

    1. Remove the 2 bolts.

    2. Disengage the claw and separate the engine room relay block.

    3. A0136C9

      Provisionally set the relay block to the hood support rod.

  16. REMOVE AIR CLEANER INLET

    A01383T

    1. Disconnect the connector.

    2. Disengage the 2 claws.

    3. Remove the air cleaner inlet.

  17. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    A013850

    1. Remove the bolt and disconnect the suction hose and air conditioning tube.

      Note

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

  18. DISCONNECT HEATER WATER INLET HOSE

    A0137ET

    1. Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water inlet hose from the heater unit.

  19. DISCONNECT HEATER WATER OUTLET HOSE

    A0138ODE01

    1. Remove the clip.

    2. Disconnect the heater water outlet hose from the heater unit.

  20. REMOVE HORN BUTTON ASSEMBLY

    A0135YBE01

    1. Place the front wheels facing straight ahead.

    2. Using "Torx" socket wrench T30, loosen the 2 screws until the screw thread catches on the screw case.

    3. A01389P

      Pull the steering pad out of the steering wheel and support the steering pad with one hand, as shown in the illustration.

      Note

      When removing the steering pad, do not pull the airbag wire harness.

    4. Disconnect the horn connector.

    5. Disconnect the airbag connector, as shown in the illustration.

      Note

      When handling the airbag connector, do not damage the airbag wire harness.

    6. Remove the steering pad.

  21. REMOVE STEERING WHEEL ASSEMBLY

    A0138CJ

    1. Remove the nut and put matchmarks on the steering wheel assembly and steering main shaft.

    2. Using SST, remove the steering wheel assembly.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  22. REMOVE STEERING COLUMN UPPER COVER

    A0136OJE02

    1. Remove the 2 screws while turning the steering wheel to the right and left.

    2. Disengage the 4 claws and remove the steering column cover upper.

    3. A0136TV

      Remove the steering column cover upper, as shown in the illustration (w/ tachometer).

    4. A0136HY

      If the steering column cover upper is difficult to remove, loosen the screw behind the tachometer, pull up and extend the tachometer, and then remove the steering cover upper (w/ tachometer).

  23. REMOVE STEERING COLUMN LOWER COVER

    A0136RZ

    1. Remove the screw and steering column lower cover.

  24. REMOVE TACHOMETER ASSEMBLY (w/ Tachometer)

    A0135U6

    1. Disconnect the connector.

    2. Remove the bolt and tachometer.

  25. REMOVE SPIRAL CABLE SUB-ASSEMBLY

    A0137TJ

    1. Disconnect the horn connector.

    2. Disconnect the airbag connector, as shown in the illustration.

      Note

      When handling the airbag connector, do not damage the airbag wire harness.

    3. Disconnect the steering angle sensor connector (w/ VSC).

    4. Disengage the 3 claws and remove the spiral cable.

  26. REMOVE COMBINATION METER ASSEMBLY

    A0137AB

    1. Remove the 2 bolts.

    2. Disconnect the 14 connectors and remove the combination meter.

  27. REMOVE COMBINATION SWITCH ASSEMBLY


    1. A01362T

      Disconnect the 3 connectors.

    2. A0138OWE01

      Remove the combination switch assembly, as shown in the illustration.

    3. A0137JG

      Disengage the 2 claws and remove the combination switch assembly.

  28. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH

    A01380D

    1. Separate the front door opening trim weatherstrip LH.

  29. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

  30. REMOVE FRONT PILLAR GARNISH LH (w/ Curtain Shield Airbag)

    Tech Tips

    Use the same procedure as for the RH side.

  31. REMOVE FRONT PILLAR GARNISH RH (w/ Curtain Shield Airbag)

    A0138EW

    1. Disengage the 2 clips and 2 claws, and remove the front pillar garnish.

    2. A0138GXE01

      Completly cover the airbag with a piece of cloth or nylon of 700 mm (27.56 in.) x 120 mm (4.72 in.) and fix the ends of the cover with adhesive tape, as shown in the illustration.

      Note

      Cover the curtain shield airbag with the protective cover as soon as the front pillar garnish is removed.

  32. REMOVE FRONT PILLAR GARNISH LH (w/o Curtain Shield Airbag)

    Tech Tips

    Use the same procedure as for the RH side.

  33. REMOVE FRONT PILLAR GARNISH RH (w/o Curtain Shield Airbag)

    A01391L

    1. Disengage the 2 clips and 2 claws, and remove the front pillar garnish.

  34. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY NO. 2

    A0136QKE01

    1. Disengage the 2 claws.

  35. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

    A01362K

    1. Remove the 2 screws.

    2. A0136BT

      Disconnect the connector.

  36. REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY NO. 1

  37. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

  38. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER

    A0136KWE02

    1. Remove the control knob.

    2. Remove the screw.

    3. Disengage the 4 clips and 3 claws and remove the cluster finish panel by pulling it up from underneath.

    4. Disconnect the connectors and remove the instrument cluster finish panel center.

  39. REMOVE INSTRUMENT PANEL ASSEMBLY

    A0136KRE02

    1. Disengage the 2 claws and open the cover.

    2. A0138UJ

      Disconnect the airbag connector, as shown in the illustration.

    3. Remove the bolt <A>, 2 nuts <D> and 2 screws <B>.

      A0137GXE01

    4. Disengage the 4 clips and 5 claws and remove the instrument panel assembly.

      A0138IQ

  40. REMOVE COWL SIDE TRIM BOARD LH


    1. A0137W2E01

      Disengage the 2 clips and claw, and remove the cowl side trim board LH.

  41. REMOVE COWL SIDE TRIM BOARD RH

  42. REMOVE HEATER CONTROL ASSEMBLY (for LHD)

    A0136DQE05

    Note

    Do not bend the cable when removing the heater control assembly.


    1. Separate the black air mix cable from the clamp and remove the cable ring from the temperature control link.

    2. Separate the white air inlet cable from the clamp and remove the cable ring from the air inlet control link.

    3. Separate the blue defroster cable from the clamp and remove it from the mode link.

    4. Remove the 2 screws, disengage the 2 claws and remove the heater control assembly.

  43. REMOVE HEATER CONTROL ASSEMBLY (for RHD)

    A01389IE04

    Note

    Do not bend the cable when removing the heater control assembly.


    1. Separate the black air mix cable from the clamp and remove the cable ring from the temperature control link.

    2. Separate the white air inlet cable from the clamp and remove the cable ring from the air inlet control link.

    3. Separate the blue defroster cable from the clamp and remove it from the mode link.

    4. Remove the 2 screws, disengage the 2 claws and remove the heater control assembly.

  44. REMOVE CONSOLE BOX

    A0137LLE01

    1. Remove the shift knob.

    2. Remove the box bottom mat.

    3. Remove the bolt <E>.

    4. Disengage the 2 claws and remove the console box.

  45. REMOVE INSTRUMENT PANEL ASSEMBLY LOWER

    A0136KRE02

    1. Disengage the 2 claws and open the cover.

    2. A0138UJ

      Disconnect the airbag connector, as shown in the illustration.

    3. Remove the bolt <A>, 2 nuts <D> and 2 screws <B>.

      A0137GXE01

    4. Disengage the 4 clips and 5 claws and remove the instrument panel assembly.

      A0138IQ

  46. REMOVE STEERING COLUMN HOLE COVER PLATE

    A0136Y5

    1. Turn back the floor carpet and disengage the 2 claws from the steering hole cover plate.

  47. REMOVE STEERING COLUMN PROTECTOR NO. 1 (RHD-E/PS-MT)

    A013808

    1. Remove the bolt and steering column protector No. 1 from the power steering motor assembly.

  48. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO. 2

    A0137IGE01

    1. Loosen bolt A.

    2. Put matchmarks, as shown in the illustration.

    3. Remove bolt B and separate the steering intermediate shaft assembly No. 2 from the steering gear assembly.

  49. REMOVE STEERING COLUMN ASSEMBLY


    1. A0136LD

      Disconnect the 2 connectors.

    2. A0137H2

      Disengage the 3 clamps and disconnect the wire harness.

    3. A0138IZ

      Remove the 3 bolts and steering column assembly.

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

    A0137AVE01

    1. Remove the clip and fold back the floor carpet.

    2. Disengage the 2 clamps.

    3. Remove the 2 wire harness clamp bolts.

    4. Remove the bolt, screw, nut and instrument panel brace sub-assembly No. 1.

  51. REMOVE TRANSPONDER KEY ECU ASSEMBLY

    A0137HA

    1. Remove the bolt.

    2. Disconnect the connector and remove the transponder key ECU assembly.

  52. REMOVE DOOR CONTROL WITH RECEIVER ECU ASSEMBLY

    A0136SW

    1. Disconnect the connector.

    2. Remove the bolt and door control with receiver ECU assembly.

  53. SEPARATE CONNECTOR HOLDER

    A0135XH

    1. Remove the screw and separate the connector holder.

  54. SEPARATE RELAY BLOCK ASSEMBLY

    A01374PE01

    1. Remove the screw.

    2. Disengage the clamp and separate the relay block assembly.

  55. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER

    A01374X

    1. Remove the bolt, nut and instrument panel to cowl brace center.

  56. REMOVE INSTRUMENT PANEL REINFORCEMENT


    1. Disengage the 7 clamps.

    2. Remove the bolt.

      A0138QPE01

    3. Remove the 6 bolts and instrument panel reinforcement.

      A0136UE

  57. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Disconnect the 3 connectors and 2 clamps.

      A01391V
    2. A01365L

      Disengage the connector lever and separate the PTC heater connector. (for Cold Area Specification Vehicles)

    3. Remove the clip, 5 nuts and air conditioner unit sub-assembly.

      A0137MX