AIR CONDITIONING UNIT (for TMMK Made) 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

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  3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. w/ Windshield Deicer System:


      1. B000HLG

        Disengage the 2 clamps.

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

    2. w/ Heated Windshield Defroster System:


      1. B000HSG

        Disengage the 4 clamps.

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

    3. B000KY4

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

    4. B000KRD

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

  4. DISCONNECT HEATER OUTLET WATER HOSE


    1. B000LMZ

      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. B000H50

      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


    1. B000MVI

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

    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 entry of moisture and foreign matter.

  7. 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 entry of moisture and foreign matter.

  8. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat)

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  9. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat)

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  10. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers)


    1. B000LCR

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

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


    1. B000MRV

      Remove the bolt and disconnect the ground wire.

    2. Disconnect each connector and disengage the clamp.

    3. B000JK5

      Remove the bolt.

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

  12. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat)

    Tech Tips

    Use the same procedure as for the LH side.

  13. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat)

    Tech Tips

    Use the same procedure as for the LH side.

  14. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

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  15. REMOVE STEERING POST ASSEMBLY

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  16. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


    1. B000IBJ

      Disconnect the 5 connectors.

    2. B000MZP

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

    3. B000NH0

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

    4. B000LBZ

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

    5. B000LNC

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

    6. Remove the instrument panel junction block assembly.

  17. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. Disconnect each connector.

    2. B000MQ7

      Remove the 2 screws.

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

  18. REMOVE FLOOR CARPET HOOK


    1. B000LIPE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disengage the 6 guides.

    2. B000KNME02
      Text in Illustration
      *A for LH Side
      *B for RH Side

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

  19. DISCONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY


    1. B000HPS

      Remove the screw.

    2. B000NNN

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

  20. REMOVE FRONT FLOOR CARPET LH


    1. B000N1KE01
      Text in Illustration
      *a Fastener

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

  21. REMOVE REAR NO. 4 AIR DUCT


    1. B000HQJ

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

  22. REMOVE FLOOR CARPET BRACKET LH


    1. B000MK1

      Remove the 2 clips.

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

  23. REMOVE REAR NO. 3 AIR DUCT


    1. B000NF9

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

  24. REMOVE FRONT FLOOR CARPET RH


    1. B000L9TE01
      Text in Illustration
      *a Fastener

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

  25. REMOVE REAR NO. 2 AIR DUCT


    1. B000J04

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

  26. REMOVE FLOOR CARPET BRACKET RH


    1. B000N1Z

      Remove the 2 clips.

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

  27. REMOVE REAR NO. 1 AIR DUCT


    1. B000NGW

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

  28. REMOVE NO. 1 CONSOLE BOX DUCT


    1. B000I7X

      Remove the clip and No. 1 console box duct.

  29. REMOVE ROOM TEMPERATURE SENSOR (COOLER THERMISTOR)


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

  30. REMOVE INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. B000HLJE01
      Text in Illustration
      *a Earth Wire

      Disengage each clamp.

    2. Remove the bolt and disconnect the earth wire.

    3. B000JIF

      Remove the bolt and 2 nuts.

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

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


    1. B000MPJE01
      Text in Illustration
      *a Earth Wire

      Disconnect each connector.

    2. Disengage each clamp.

    3. Remove the bolt and disconnect the earth wire.

    4. B000KVT

      Remove the bolt and 2 nuts.

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

  32. REMOVE INSTRUMENT PANEL SAFETY PAD CAP


    1. B000K43E02
      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.

  33. REMOVE FRONT LOWER PANEL PACKING


    1. B000N91

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

  34. 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. B000HHE

        Disengage the 3 clamps.

    2. B000KTM

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

    3. B000IRXE03
      Text in Illustration
      *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.

    4. Disconnect each connector.

    5. Disengage each clamp.

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

      B000LMHE03
      Text in Illustration
      *a Retainer *b Protective Tape

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

      B000K1N

    8. Disengage each clamp.

      B000M4WE01
      Text in Illustration
      *a Earth Wire - -

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

    10. B000HDR

      Disengage each clamp.

    11. Remove the bolt and disconnect the earth wire.

      B000IT3E03
      Text in Illustration
      *a Earth Wire *b Connector Holder

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

    13. Disconnect the connector.

    14. Disengage each clamp.

    15. B000K0L

      Remove the 2 bolts.

    16. B000IFD

      Disconnect the drain cooler hose.

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

      B000HLDE01
      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 - -

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

      B000N8O

  35. REMOVE AIR CONDITIONING UNIT ASSEMBLY


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

      B000LFO