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. A003CF6

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

  6. REMOVE COWL VENT COVER LH


    1. A003HZ5

      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. A003HAVE01

      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. A003G43E01

      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 (for 2KD-FTV)

    CAUTION:

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


    1. Loosen the radiator drain cock plug.

      A003IDXE01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    2. Remove the radiator reservoir cap sub-assembly.

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

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock plug (on the engine oil cooler cover).

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

  11. DRAIN ENGINE COOLANT (for 2TR-FE)

    CAUTION:

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

    Tech Tips

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


    1. Loosen the radiator drain cock plug and drain the engine coolant.

      A003AWAE01
      Text in Illustration
      *A w/ Dual VVT-i *B w/o Dual VVT-i
      *1 Radiator Reservoir Cap Sub-assembly *2 Radiator Reservoir Assembly
      *3 Radiator Drain Cock Plug *4 Cylinder Block Water Drain Cock Plug
      *5 2-Way - -

    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block water drain cock plug and drain the engine coolant from the engine.

  12. DRAIN ENGINE COOLANT (for 2TR-FE)

    A003F1ME01

    CAUTION:

    To avoid the danger of being burned, do not remove the reservoir cap 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. Loosen the radiator drain plug.

    2. Remove the reservoir cap.

    3. Loosen the cylinder block drain plug and drain the coolant.

    4. Tighten the radiator drain plug.

    5. Tighten the cylinder block drain plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  13. DRAIN ENGINE COOLANT (for 1GD-FTV)

    CAUTION:

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


    1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock.

    2. Loosen the radiator drain cock plug.

      A003DK2E03
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Cap Sub-assembly
      *3 Radiator Reserve Tank Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    3. Remove the radiator cap sub-assembly.

    4. Loosen the cylinder block drain cock plug, and drain the engine coolant.

    5. Tighten the radiator drain cock plug.

    6. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    7. Disconnect the hose from the radiator drain cock.

  14. REMOVE RADIATOR GRILLE (for Standard Body)


    1. A003BRDE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the radiator grille.

    2. A003DGE

      Remove the 4 clips and 2 screws.

    3. Detach the 8 claws and remove the radiator grille.

  15. REMOVE RADIATOR GRILLE (for Wide Body)

    A003GGIE01

    1. Put protective tape around the radiator grille.

      Text in Illustration
      *1 Protective Tape
    2. A003G9X

      Remove the 4 clips and 2 screws.

    3. Detach the 10 claws and remove the radiator grille.

  16. REMOVE NO. 2 AIR INLET DUCT (w/ Intercooler)


    1. A003FDS

      Detach the 3 clips and remove the No. 2 air inlet duct.

  17. REMOVE NO. 1 AIR INLET DUCT (w/ Intercooler)


    1. A003BHG

      Detach the 2 clips.

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

  18. DRAIN WINDSHIELD WASHER FLUID (w/ Intercooler)

  19. REMOVE WINDSHIELD WASHER JAR ASSEMBLY


    1. A003F7D

      Disconnect the washer hose.

    2. Detach the clamp.

    3. Remove the 2 bolts and windshield washer jar.

    4. A003B5N

      Disconnect the washer hose.

    5. Detach the clamp.

    6. Disconnect the 2 connectors.

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


    1. A003EKO

      Disconnect the water by-pass hose.

    2. Remove the bolt and radiator reserve tank.

    3. A003DFZ

      Disconnect the No. 2 water by-pass hose.

  21. REMOVE HOOD LOCK ASSEMBLY (w/ Intercooler)


    1. A003HM8

      Remove the 3 bolts and hood lock.

    2. A003E9U

      Disconnect the hood lock control cable.

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


    1. A003B1W

      Remove the hood lock control cable from the 2 clamps.

    2. A003HMD

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

  23. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. A003ECE

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

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

    3. Remove the 3 bolts and intercooler.

  24. DISCONNECT COOLER REFRIGERANT SUCTION PIPE A


    1. A003E5VE01
      Text in Illustration
      *1 Cooler Refrigerant Suction Pipe A
      *2 Hook Connector
      *3 Cooler Refrigerant Liquid Pipe B

      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.

  25. 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.

  26. DISCONNECT HEATER WATER HOSE OUTLET


    1. A003BGKE01
      Text in Illustration
      *1 Heater Outlet Water Hose
      *2 Heater Water Inlet Hose A

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

  27. 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.

  28. REMOVE INSTRUMENT PANEL ASSEMBLY

    Click here

  29. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  30. REMOVE AIR DUCT NO.1


    1. A003BPGE01

      Remove the clip.

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

  31. DISCONNECT PARKING BRAKE CONTROL HANDLE SUB-ASSEMBLY


    1. A003AI3

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

  32. REMOVE INSTRUMENT PANEL TO FLOOR BRACE SUB-ASSEMBLY


    1. A003IAW

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

  33. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

      A003CL9E01

    2. Remove the bolts, nuts and junction blocks.

    3. Remove the 2 caps and 2 bolts.

      A003FKEE02
      Text in Illustration
      *A for Manual Transmission - -
      *1 ''Torx'' Bolt *2 Collar

    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.

  34. REMOVE AIR CONDITIONER UNIT ASSEMBLY


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

      A003BQE

  35. REMOVE AIR DUCT NO.2


    1. A003ALNE01

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

  36. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. A003DGP

      w/ PTC


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

    2. A003GZR

      Remove the 3 screws and air conditioning radiator assembly.