AIR CONDITIONING UNIT REMOVAL

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  3. DRAIN ENGINE COOLANT (for 1ZR-FAE)

    Click here

  4. DRAIN ENGINE COOLANT (for 2ZR-FAE)

    Click here

  5. DRAIN ENGINE COOLANT (for 1WW)

    Click here

  6. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    Note

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

  8. REMOVE NO. 2 CYLINDER HEAD COVER (for ZR Series Engine)

    Click here

  9. REMOVE NO. 1 ENGINE COVER (for 1WW)

    Click here

  10. REMOVE FRONT WIPER ARM HEAD CAP

    Click here

  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

    Click here

  12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

    Click here

  13. REMOVE HOOD TO COWL TOP SEAL

    Click here

  14. REMOVE COWL TOP VENTILATOR LOUVER LH

    Click here

  15. REMOVE COWL TOP VENTILATOR LOUVER RH

    Click here

  16. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  17. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)

    Click here

  18. REMOVE OUTER COWL TOP PANEL

    Click here

  19. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for HFC-134a(R134a))


    1. A002OO3

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

  20. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for HFC-134a(R134a))


    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.

  21. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (for HFO-1234yf(R1234yf))


    1. A002NUT

      Remove the bolt and slide the hook connector.

    2. Disconnect the air conditioning tube and accessory assembly.

    3. Remove the 2 O-rings 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.

  22. DISCONNECT HEATER OUTLET WATER HOSE AND HEATER INLET WATER HOSE


    1. A002PLY

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

      Note


      • Do not apply excessive force to the heater hose.

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

  23. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  24. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  25. REMOVE FRONT DOOR SCUFF PLATE LH

    Click here

  26. REMOVE COWL SIDE TRIM BOARD LH

    Click here

  27. REMOVE FRONT DOOR SCUFF PLATE RH

    Click here

  28. REMOVE COWL SIDE TRIM BOARD RH

    Click here

  29. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  30. REMOVE REAR NO. 3 AIR DUCT


    1. A002M78

      Remove the clip.

    2. Fold back the floor carpet.

    3. A002OJG

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

  31. REMOVE REAR NO. 1 AIR DUCT


    1. A002MB1

      Remove the clip.

    2. Fold back the floor carpet.

    3. A002P1M

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

  32. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A002NR2

      Remove the 2 nuts and No. 1 air duct sub-assembly.

  33. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A002MZE

      Detach the 6 claws and remove the lower defroster nozzle assembly.

  34. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE


    1. A002M1Y

      Remove the 2 bolts and center instrument panel to cowl brace.

  35. REMOVE INSTRUMENT PANEL BRACE ASSEMBLY

    A002Q5KE03
    Text in Illustration
    *1 except Manual Transaxle

    1. Disconnect the connector.

    2. Detach each clamp.

    3. Remove the 2 screws.

    4. Remove the 3 bolts, 2 nuts and instrument panel brace assembly.

  36. REMOVE REAR NO. 2 AIR DUCT


    1. A002PBR

      Detach the 4 claws and remove the rear No. 2 air duct.

  37. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Remove the 2 bolts and ground wire.

    2. Detach each clamp and disconnect the wire harness.

      A002N6V

    3. Disconnect each connector.

    4. Detach each clamp.

    5. Remove each bolt, and disconnect the wire harness and junction block.

      A002MLGE02
      Text in Illustration
      *A except Manual Transaxle *B w/ PTC Heater

    6. Remove the 8 bolts and instrument panel reinforcement assembly.

      A002OFW

  38. REMOVE AIR CONDITIONING UNIT

    A002OL0

    1. Disconnect the drain cooler hose.

    2. Remove the bolt, nut and air conditioning unit.

      Note


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

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

  39. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A002OXP

      Detach the 2 claws and remove the No. 2 air duct sub-assembly.

  40. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A002PUX

      Detach the 2 claws and remove the No. 3 air duct sub-assembly.

  41. REMOVE BLOWER ASSEMBLY

    Click here