AIR CONDITIONING UNIT REMOVAL

Note

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


  1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM


    1. Turn the A/C switch on.

    2. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.

    3. Turn the ignition switch off.

    4. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01I1IF

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

    2. A01HY4M

      Remove the 10 bolts and front outer cowl top panel sub-assembly.

  4. DISCONNECT HEATER OUTLET WATER HOSE


    1. A01HZTH

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

      Note


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

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

  5. DISCONNECT HEATER INLET WATER HOSE


    1. A01I18A

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

      Note


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

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

  6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made)


    1. A01I1PR

      Remove the bolt and rotate 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 the entry of moisture and foreign matter.

  7. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made)


    1. A01I1PR

      Remove the bolt and rotate the hook connector.

    2. Disconnect the suction pipe sub-assembly.

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

      Note

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

  8. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Disconnect the air conditioner tube and accessory assembly.

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

      Note

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

  9. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat)

    Click here

  10. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat)

    Click here

  11. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat)

    Click here

  12. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat)

    Click here

  13. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers)


    1. A01I1DC

      Using a clip remover, remove the 2 clips and audio amplifier cover.

  14. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers)


    1. A01I17D

      Remove the bolt and disconnect the ground wire.

    2. Disconnect each connector and disengage the clamp.

    3. A01I11W

      Remove the bolt.

    4. Disengage the 2 guides and remove the stereo component amplifier assembly with bracket.

  15. REMOVE FRONT SEAT ASSEMBLY RH (for TMMK Made Manual Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  16. REMOVE FRONT SEAT ASSEMBLY RH (for TMMK Made Power Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  17. REMOVE FRONT SEAT ASSEMBLY RH (for SIA Made Manual Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  18. REMOVE FRONT SEAT ASSEMBLY RH (for SIA Made Power Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  19. REMOVE AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch)


    1. A01I0L1

      Using a clip remover, remove the 2 clips and audio amplifier cover.

  20. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch)


    1. A01HZRR

      Disconnect each connector.

    2. Disengage the 3 clamps.

    3. A01I27N

      Remove the bolt.

    4. Disengage the 2 guides and remove the DCM (telematics transceiver) with back-up battery.

  21. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  22. REMOVE STEERING POST ASSEMBLY

    Click here

  23. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


    1. A01I210

      Disconnect the 5 connectors.

    2. A01I1O9

      Remove the bolt and 2 nuts, and disconnect the instrument panel junction block assembly.

    3. A01HYV7

      Disengage the claw and disconnect the connector as shown in the illustration.

    4. A01HYCJ

      Disengage the claw and release the connector lock as shown in the illustration.

    5. A01I1SV

      Disengage the claw and disconnect the connector as shown in the illustration to remove the instrument panel junction block assembly.

  24. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/ Smart Key System)

    w/o ECU Integration Box RH: Click here

  25. REMOVE ECU INTEGRATION BOX RH (w/ ECU Integration Box RH)


    1. A01I0WT

      Disconnect each connector and disengage the clamp.

    2. Remove the bolt, 2 nuts and the ECU integration box RH.

  26. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. Disconnect each connector.

    2. A01I1AP

      Remove the 2 screws.

    3. Disengage the 2 guides to remove the air conditioning amplifier assembly.

  27. REMOVE GLASS BREAKAGE SENSOR ECU (w/ Glass Breakage Sensor)


    1. Disconnect the connector.

    2. A01HZW0

      Remove the nut and glass breakage sensor ECU.

  28. REMOVE REMOTE ENGINE STARTER ECU (w/ Remote Engine Starter System)


    1. Disconnect the connector.

    2. A01HZ0Y

      Remove the nut and remote engine starter ECU.

  29. REMOVE FLOOR CARPET HOOK


    1. A01HZWVE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disengage the 6 guides.

    2. A01HYT8E02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disengage the 6 claws and remove the 6 floor carpet hooks.

  30. DISCONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY


    1. A01I01O

      Remove the screw.

    2. A01HYWI

      Disengage the guide to disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

  31. REMOVE FRONT FLOOR CARPET LH


    1. A01I09FE01
      Text in Illustration
      *a Fastener

      Disengage the guide and each fastener, and remove the front floor carpet LH.

  32. REMOVE REAR NO. 4 AIR DUCT


    1. A01HYJ5

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

  33. REMOVE FLOOR CARPET BRACKET LH


    1. A01I0KA

      Remove the 2 clips.

    2. Disengage the 2 guides to remove the floor carpet bracket LH.

  34. REMOVE REAR NO. 3 AIR DUCT


    1. A01I0UD

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

  35. REMOVE FRONT FLOOR CARPET RH


    1. A01HYABE01
      Text in Illustration
      *a Fastener

      Disengage the guide and each fastener, and remove the front floor carpet RH.

  36. REMOVE REAR NO. 2 AIR DUCT


    1. A01HXUJ

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

  37. REMOVE FLOOR CARPET BRACKET RH


    1. A01HZ44

      Remove the 2 clips.

    2. Disengage the 2 guides to remove the floor carpet bracket RH.

  38. REMOVE REAR NO. 1 AIR DUCT


    1. A01I0RI

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

  39. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct)


    1. A01HZX8

      Remove the clip and No. 1 console box duct.

  40. REMOVE ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) (for Automatic Air Conditioning System)


    1. Disconnect the cooler thermistor hose and connector, and remove the room temperature sensor (cooler thermistor).

  41. REMOVE INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. A01HZ33E01
      Text in Illustration
      *a Earth Wire

      Disconnect the connector.

    2. Disengage each clamp.

    3. Remove the bolt and disconnect the earth wire.

    4. A01HZUI

      Remove the bolt and 2 nuts.

    5. Remove the screw and instrument panel to cowl brace sub-assembly.

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


    1. A01I25FE01
      Text in Illustration
      *a Earth Wire

      Disconnect each connector.

    2. Disengage each clamp.

    3. Remove the bolt and disconnect the earth wire.

    4. A01HYHZ

      Remove the bolt and 2 nuts.

    5. Remove the screw and No. 2 instrument panel brace sub-assembly.

  43. REMOVE INSTRUMENT PANEL SAFETY PAD CAP


    1. A01HYVEE02
      Text in Illustration
      *A for LH Side
      *B for RH Side
      *a Protective Tape

      Put protective tape around the 5 instrument panel safety pad caps.

    2. Using a screwdriver, remove the 5 instrument panel safety pad caps as shown in the illustration.

  44. REMOVE FRONT LOWER PANEL PACKING


    1. A01I1JW

      Remove the 2 front lower panel packings as shown in the illustration.

  45. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    Note


    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.

    • When disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. for 10 Speakers:


      1. A01HY7G

        Disengage the 3 clamps.

    2. w/ Manual (SOS) Switch:


      1. A01I1JP

        Disengage the clamp.

    3. A01I1PX

      Disengage the 3 claws to open the 3 clamps as shown in the illustration.

    4. A01HY3JE01
      Text in Illustration
      *A w/ Smart Key System
      *1 Airbag Sensor Assembly

      Disconnect the connector from the airbag sensor assembly as shown in the illustration.

      Note

      When disconnecting any airbag connector, take care not to damage the airbag wire harness.

    5. Disconnect each connector.

    6. Disengage each clamp.

    7. Using a screwdriver, disengage the 2 claws to unlock the retainer as shown in the illustration.

      A01I1KIE03
      Text in Illustration
      *a Retainer *b Protective Tape

    8. Disengage the claw and disconnect the airbag connector as shown in the illustration.

      A01HXQK

    9. Disengage each clamp.

      A01HZAGE01
      Text in Illustration
      *a Earth Wire - -

    10. Remove the 2 bolts and disconnect the 2 earth wires.

    11. A01HYBW

      Disengage each clamp.

    12. Remove the bolt and disconnect the earth wire.

      A01HZGXE03
      Text in Illustration
      *a Earth Wire *b Connector Holder

    13. Remove the 2 nuts and disconnect the connector holder.

    14. Disconnect the connector.

    15. Disengage each clamp.

    16. A01I02V

      Remove the 2 bolts.

    17. A01HZG1

      Disconnect the drain cooler hose.

    18. Remove the 6 bolts and nut as shown in the illustration.

      A01I12QE01
      Text in Illustration
      *1 Movable Collar *2 Instrument Panel Reinforcement Assembly
      *a Vehicle Body *b Step 1
      *c Step 2 *d Step 3
      *e Step 4 - -

    19. Disengage the 3 guides and remove the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

      A01HZ5DE01
      Text in Illustration
      *A w/ Engine Immobiliser System - -

    20. w/ Engine Immobiliser System:


      1. Disengage the claw and 2 guides, and disconnect the transponder key ECU assembly as shown in the illustration.

  46. REMOVE TRANSPONDER KEY ECU ASSEMBLY (w/ Engine Immobiliser System)


    1. A01HXH4

      Disconnect the connector and remove the transponder key ECU assembly.

  47. REMOVE AIR CONDITIONING UNIT ASSEMBLY


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

      A01HY6J