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)

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    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. B0041XB

      Remove the bolt and cooler cap.

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


    1. w/o Sub-cool Accelerator:


      1. B0044QX

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

      2. B0044YR

        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. w/o Sub-cool Accelerator:


      1. B0042J7

        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 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Cooler System)


    1. w/ Sub-cool Accelerator:


      1. B0044RN

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

      2. B0044OT

        Disconnect the air conditioner tube and accessory assembly.

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

        Note

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

  11. DISCONNECT HEATER WATER OUTLET HOSE A


    1. B00437C

      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.

  12. DISCONNECT HEATER WATER INLET HOSE A


    1. B004295

      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.

  13. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  14. REMOVE STEERING COLUMN ASSEMBLY

    Click here

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

    Click here

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

    Click here

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

    w/ Cruise Control System:

    Click here

  18. REMOVE TELEMATICS TRANSCEIVER (w/ Manual (SOS) Switch)

    Click here

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

    B0043QF

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

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


    1. B00454F

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

  21. REMOVE DEFROSTER NOZZLE ASSEMBLY


    1. B0042NE

      Disengage the 6 claws and remove the defroster nozzle assembly.

  22. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE

    B0044G2

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

  23. DISCONNECT INSTRUMENT PANEL WIRE (for LHD)


    1. for Cold Area:


      1. B0043U0

        Disconnect the 2 connectors.

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

      B0043MVC01
      *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
      B0042CO Bolt <A> B0043VS Bolt <B>
      B0043HC Bolt <C> B00420Y 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.

  24. DISCONNECT INSTRUMENT PANEL WIRE (for RHD)


    1. for Cold Area:


      1. B0043BS

        Disconnect the 2 connectors.

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

      B0042USC01
      *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
      B0042CO Bolt <A> B0043VS Bolt <B>
      B0043HC Bolt <C> B00420Y 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.

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


    1. B0044JP

      Using a clip remover, remove the clip.

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

    3. B004273C01
      B0042CO Bolt
      B0043VS Screw
      B0043HC Nut

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

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


    1. B0043HZ

      Using a clip remover, remove the clip.

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

    3. B0044E7C01
      B0042CO Bolt
      B0043VS Screw
      B0043HC Nut

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

  27. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

      B0042DV

  28. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Disconnect the drain cooler hose.

      B0043CIC01
      B0043VS Bolt B0043HC Nut

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

  29. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. B0041N8

      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.

  30. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. B00439G

      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.

  31. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. for Cold Area:


      1. B0043MB

        Remove the screw.

      2. Disengage each clamp and disconnect the wire harness.

    2. for Automatic Air Conditioning System:


      1. Disconnect the connector.

        B00422DC01
        *A for Automatic Air Conditioning System - -

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

  32. REMOVE HEATER COVER (except Cold Area)


    1. B0042UD

      Disengage the 4 claws to remove the heater cover.

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


    1. B0042OS

      Disengage the 2 claws to remove the aspirator pipe.

  34. REMOVE ASPIRATOR (for Automatic Air Conditioning System)


    1. for LHD:


      1. B004425

        Disengage the 2 claws to remove the aspirator.

    2. for RHD:


      1. B0044ZK

        Disengage the clamp.

      2. Disengage the 2 claws to remove the aspirator.

  35. REMOVE CONSOLE MOUNTING BRACKET LH


    1. B0042FQ

      Remove the screw and console mounting bracket LH.

  36. REMOVE CONSOLE MOUNTING BRACKET RH


    1. B00450P

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

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


    1. B0041U7

      Remove the screw.

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

      B0042IM

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


    1. B0044G0

      Disconnect the connector.

    2. Remove the screw.

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

      B0042H9

  39. REMOVE DRAIN COOLER HOSE


    1. B00436O

      Remove the drain cooler hose.

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


    1. Disengage each clamp.

      B0041X2C01
      *A for Dual Type - -

    2. Disconnect each connector.

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