AIR CONDITIONING UNIT REMOVAL

Note

Make sure to select FACE mode before disconnecting the cable from the negative (-) battery terminal.


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  3. REMOVE OUTER COWL TOP PANEL


    1. A01EIQY

      Disengage the 2 clamps and separate the wiper wire harness from the outer cowl top panel sub-assembly.

    2. A01EKSW

      Disengage the 2 clamps and connector, and separate the wire harness from the outer cowl top panel sub-assembly (w/ Windshield Deicer).

    3. A01EL1AE01
      Text in Illustration
      *1 Bolt
      *2 Nut

      Remove the 4 bolts, 4 nuts and outer cowl top panel sub-assembly.

  4. DISCONNECT OUTLET HEATER WATER HOSE


    1. A01EMDA

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

      Note


      • Do not apply excessive force to the outlet heater water hose.

      • Prepare a drain pan or cloth in case the coolant leaks.

  5. DISCONNECT INLET HEATER WATER HOSE


    1. A01EKJ3

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

      Note


      • Do not apply excessive force to the inlet heater water hose.

      • Prepare a drain pan or cloth in case the coolant leaks.

  6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A01EJJB

      Remove the bolt, and slide the hook connector.

    2. Disconnect the suction hose sub-assembly.

    3. Remove the O-ring from the suction hose sub-assembly.

      Note

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

  7. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Disconnect the air conditioning tube and accessory assembly.

    2. Remove the O-ring from the air conditioning tube and accessory assembly.

      Note

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

  8. REMOVE FRONT SEAT ASSEMBLY LH

    Click here

  9. REMOVE FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  10. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  11. REMOVE STEERING POST ASSEMBLY

    Click here

  12. REMOVE TURN SIGNAL FLASHER ASSEMBLY


    1. A01ELOA

      Disconnect the connector.

    2. Disengage the clamp and remove the turn signal flasher assembly.

  13. REMOVE POWER MANAGEMENT CONTROL ECU


    1. A01EL48

      Disconnect the 2 connectors.

    2. Remove the 2 nuts and the power management control ECU.

  14. REMOVE 4WD CONTROL ECU (for 4WD)


    1. A01EK3T

      Disconnect the connector.

    2. A01EIR4

      Remove the 2 nuts and ECU.

  15. REMOVE MAIN BODY ECU (DRIVER SIDE JUNCTION BLOCK ASSEMBLY)


    1. Separate the wire harness clamp from the driver side junction block assembly.

    2. Disconnect the connectors from the driver side junction block assembly.

    3. A01EMEI

      Remove the 3 nuts.

    4. Disconnect the connectors from the back of the driver side junction block assembly.

    5. A01ELOW

      Disengage the 2 claws to remove the driver side junction block assembly.

  16. REMOVE POWER STEERING ECU ASSEMBLY


    1. A01EIYN

      Disconnect the 3 connectors from the power steering ECU assembly.

    2. A01ELGB

      Disconnect the connector from the power steering ECU assembly.

      Tech Tips

      Pull out the lock of the lock lever, disengage the claw, and raise the lock lever to disconnect the connector as shown in the illustration.

    3. A01EL1O

      Remove the 3 nuts and power steering ECU assembly.

    4. A01EJ63

      Disengage the 4 wire harness clamps from the power steering ECU assembly

  17. REMOVE REAR NO. 2 AIR DUCT


    1. Turn back the floor carpet.

    2. A01ELSO

      Disengage the 4 claws and remove the rear No. 2 air duct as shown in the illustration.

  18. REMOVE REAR NO. 1 AIR DUCT


    1. A01EJA3

      Disengage the 2 claws and remove the rear No. 1 air duct.

  19. REMOVE FLOOR CARPET BRACKET LH


    1. A01EKYA

      Disengage the 2 clamps.

    2. Remove the 3 clips and floor carpet bracket LH.

  20. REMOVE REAR NO. 4 AIR DUCT


    1. Turn back the floor carpet.

    2. A01EL7S

      Disengage the 4 claws and remove the rear No. 4 air duct as shown in the illustration.

  21. REMOVE REAR NO. 3 AIR DUCT


    1. A01EIX4

      Disengage the 2 claws and remove the rear No. 3 air duct.

  22. REMOVE FLOOR CARPET BRACKET RH


    1. A01EJCK

      Remove the 3 clips and floor carpet bracket RH.

  23. REMOVE NO. 1 CONSOLE BOX DUCT


    1. A01ELKG

      Remove the clip and No. 1 console box duct as shown in the illustration.

  24. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A01ELJI

      Disengage the clamp.

    2. Disengage the 4 claws and remove the No. 6 heater to register duct assembly.

  25. REMOVE NO. 3 INSTRUMENT PANEL REINFORCEMENT


    1. A01EIXPE01
      Text in Illustration
      *1 Bolt
      *2 Nut
      *3 Earth Wire

      Disengage the clamp.

    2. Remove the bolt and disconnect the earth wire.

    3. Remove the 2 nuts and No. 3 instrument panel reinforcement.

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


    1. A01EKJE

      Disengage each clamp.

    2. A01EIRGE01
      Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut
      *4 Earth Wire

      Remove the screw.

    3. Remove the bolt and disconnect the earth wire.

    4. Remove the 2 bolts, 2 nuts and No. 1 instrument panel brace sub-assembly.

  27. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. A01ELFRE01
      Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut
      *4 Earth Wire

      Disengage each clamp.

    2. Remove the screw.

    3. Remove the bolt and disconnect the earth wire.

    4. Remove the bolt, 2 nuts and No. 2 instrument panel brace sub-assembly.

  28. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY


    1. Remove the bolt, 2 nuts and screw.

      A01ELAZE01
      Text in Illustration
      *1 Bolt *2 Nut
      *3 Screw *4 Blower Motor Connector

    2. Disconnect the blower motor connector.

    3. Disconnect each connector.

    4. Disengage each clamp.

    5. Remove the 2 bolts from the engine compartment side.

      A01EJSJE01
      Text in Illustration
      *1 Bolt *2 Nut
      *3 Cooler Drain Hose - -

    6. Remove the nut.

    7. Disconnect the cooler drain hose.

    8. for LH side:


      1. A01EM12

        Remove the hole plug.

    9. for RH side:


      1. A01ELGV

        Remove the hole plug.

    10. Using a T40 "TORX" socket wrench, remove the 4 "TORX" bolts.

      A01EKFGE01
      Text in Illustration
      *1 "TORX" Bolt *2 Collar
      *3 Bolt - -

      Tech Tips

      The "TORX" bolts on the passenger side may be removed with the collars for adjustment.

    11. Using a 12 mm hexagon wrench, remove the 2 collars.

    12. Remove the bolt and instrument panel reinforcement assembly with air conditioning unit assembly.

  29. REMOVE AIR CONDITIONING UNIT ASSEMBLY


    1. Remove the 3 nuts and air conditioning unit assembly from the instrument panel reinforcement assembly.

      A01EJMO