AIR CONDITIONING UNIT REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

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

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Cooler System)

    Click here

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 1WW, 1ND-TV)

    Click here

  4. REMOVE WATER GUARD PLATE LH (for 1WW, 1ND-TV)

    for LHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

    for RHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for 1WW, 1ND-TV)

    for LHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

    for RHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  6. REMOVE OUTER COWL TOP PANEL (for 1WW, 1ND-TV)

    for LHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

    for RHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  7. REMOVE COOLER CAP (w/o Cooler System)


    1. A01M04F

      Remove the bolt and cooler cap.

  8. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Cooler System)


    1. A01LW2Z

      Remove the bolt and rotate the hook connector as shown in the illustration.

    2. A01LY34

      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.

  9. DISCONNECT AIR CONDITIONER TUBE ASSEMBLY (w/ Cooler System)


    1. A01M1SY

      Disconnect the air conditioner tube assembly.

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

      Note

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

  10. DISCONNECT HEATER WATER OUTLET HOSE A


    1. A01M21U

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

      Note


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

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

  11. DISCONNECT HEATER WATER INLET HOSE A


    1. A01LYZD

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

      Note


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

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

  12. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  13. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  14. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for LHD)

    Click here

  15. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for RHD)

    Click here

  16. REMOVE DRIVING SUPPORT ECU ASSEMBLY (for 1ND-TV)

    w/ Cruise Control System:

    Click here

  17. REMOVE REAR NO. 1 AIR DUCT (for Cold Area)

    A01M1CQ

    1. Disengage the 8 claws and remove the rear No. 1 air duct.

  18. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)


    1. A01LYW0

      Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.

  19. REMOVE DEFROSTER NOZZLE ASSEMBLY


    1. A01LY2B

      Disengage the 6 claws and remove the defroster nozzle assembly.

  20. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE

    A01M376

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

  21. DISCONNECT INSTRUMENT PANEL WIRE (for LHD)


    1. for Cold Area:


      1. A01M2CL

        Disconnect the 2 connectors.

    2. Remove the 2 bolts <A> and disconnect the ground portion of the wiring harness protector cover and earth wire.

      A01LW2CC01
      *A w/ ECU Integration Box RH *B w/o Radio Receiver
      *C for Automatic Air Conditioning System *D for Manual Air Conditioning System
      *a Ground Portion of the Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01M03W Bolt <A> A01LZQW Bolt <B>
      A01LWTP Bolt <C> A01M0E2 Connector

    3. Remove the 5 bolts <B>.

    4. w/ ECU Integration Box RH:


      1. Remove the 3 bolts <C>.

      2. Disengage the guide and disconnect the ECU integration box RH.

    5. Disconnect each connector.

    6. Disengage each clamp and disconnect the instrument panel wire.

  22. DISCONNECT INSTRUMENT PANEL WIRE (for RHD)


    1. for Cold Area:


      1. A01M2B4

        Disconnect the 2 connectors.

    2. Remove the 2 bolts <A> and disconnect the ground portion of the wiring harness protector cover and earth wire.

      A01LXRTC01
      *A w/ ECU Integration Box RH *B w/o Radio Receiver
      *C for Manual Air Conditioning System *D for Automatic Air Conditioning System
      *a Ground Portion of the Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01M03W Bolt <A> A01LZQW Bolt <B>
      A01LWTP Bolt <C> A01M0E2 Connector

    3. Remove the 4 bolts <B>.

    4. w/ ECU Integration Box RH:


      1. Remove the 3 bolts <C>.

      2. Disengage the guide and disconnect the ECU integration box RH.

    5. Disconnect each connector.

    6. Disengage each clamp and disconnect the instrument panel wire.

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


    1. A01M2X3

      Using a clip remover, remove the clip.

    2. Turn back the front floor carpet assembly as shown in the illustration.

    3. A01LYJ8C01
      A01M03W Bolt
      A01LZQW Screw
      A01LWTP Nut

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

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


    1. A01M10N

      Using a clip remover, remove the clip.

    2. Turn back the front floor carpet assembly as shown in the illustration.

    3. A01M304C01
      A01M03W Bolt
      A01LZQW Screw
      A01LWTP Nut

      Remove the bolt, screw, nut and No. 2 instrument panel brace sub-assembly.

  25. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

      A01LZ4N

  26. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Disconnect the drain cooler hose.

      A01M2QDC01
      A01LZQW Bolt A01LWTP Nut

    2. Remove the bolt, nut and air conditioner unit assembly.

  27. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A01LX1X

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

      Note

      If any of the claws of the No. 2 air duct sub-assembly have been cracked or deformed during removal, make sure to replace the air duct with a new one. Failure to do so may cause the No. 2 air duct sub-assembly to fall off or noise to occur.

  28. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01M07Z

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

      Note

      If any of the claws of the No. 3 air duct sub-assembly have been cracked or deformed during removal, make sure to replace the air duct with a new one. Failure to do so may cause the No. 3 air duct sub-assembly to fall off or noise to occur.

  29. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. for Cold Area:


      1. A01M2SV

        Remove the screw.

      2. Disengage each clamp and disconnect the wire harness.

    2. for Automatic Air Conditioning System:


      1. Disconnect the connector.

        A01M2MDC01
        *A for Automatic Air Conditioning System - -

    3. Remove the 3 screws and air conditioning radiator assembly.

  30. REMOVE HEATER COVER (except Cold Area)


    1. A01LWJ2

      Disengage the 4 claws to remove the heater cover.

  31. REMOVE ASPIRATOR PIPE (w/o Cooler System)


    1. A01M2QA

      Disengage the 2 claws to remove the aspirator pipe.

  32. REMOVE ASPIRATOR (for Automatic Air Conditioning System)


    1. for LHD:


      1. A01LZOJ

        Disengage the 2 claws to remove the aspirator.

    2. for RHD:


      1. A01LUVE

        Disengage the clamp.

      2. Disengage the 2 claws to remove the aspirator.

  33. REMOVE CONSOLE MOUNTING BRACKET LH


    1. A01LYV2

      Remove the screw and console mounting bracket LH.

  34. REMOVE CONSOLE MOUNTING BRACKET RH


    1. A01M0Q0

      Disengage the 2 claws to remove the console mounting bracket RH.

  35. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (for Manual Air Conditioning System)


    1. A01LWBP

      Remove the screw.

    2. Remove the air conditioning amplifier assembly as shown in the illustration.

      A01LXYP

  36. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (for Automatic Air Conditioning System)


    1. A01LVDQ

      Disconnect the connector.

    2. Remove the screw.

    3. Remove the air conditioning amplifier assembly as shown in the illustration.

      A01LVWU

  37. REMOVE DRAIN COOLER HOSE


    1. A01M1ME

      Remove the drain cooler hose.

  38. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)


    1. Disengage each clamp.

      A01LVXOC01
      *A for Dual Type - -

    2. Disconnect each connector.

    3. Remove the air conditioning harness assembly as shown in the illustration.