AIR CONDITIONING UNIT REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

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

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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  3. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A01KU1Q

      Remove the bolt and rotate the hook connector.

    2. A01KSD2

      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.

  4. DISCONNECT AIR CONDITIONER TUBE ASSEMBLY


    1. A01KTE0

      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 the entry of moisture and foreign matter.

  5. DISCONNECT HEATER WATER OUTLET HOSE A


    1. A01KROI

      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.

  6. DISCONNECT HEATER WATER INLET HOSE A


    1. A01KT19

      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.

  7. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

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  8. REMOVE STEERING COLUMN ASSEMBLY

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

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

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

    A01KR9A

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

  12. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. A01KR1C

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

  13. REMOVE DEFROSTER NOZZLE ASSEMBLY


    1. A01KTKM

      Disengage the 6 claws and remove the defroster nozzle assembly.

  14. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE

    A01KT8V

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

  15. DISCONNECT INSTRUMENT PANEL WIRE (for LHD)


    1. for Cold Area:


      1. A01KS2Y

        Disconnect the 2 connectors.

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

      A01KTUSC02
      *a Ground Portion of the Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01KRLR Bolt <A> A01KR22 Bolt <B>
      A01KSJJ Bolt <C> A01KT9A Connector

    3. Remove the 5 bolts <B>.

    4. Remove the 3 bolts <C>.

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

    6. Disconnect each connector.

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

  16. DISCONNECT INSTRUMENT PANEL WIRE (for RHD)


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

      A01KRZJC02
      *a Ground Portion of the Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01KRLR Bolt <A> A01KR22 Bolt <B>
      A01KSJJ Bolt <C> A01KT9A Connector

    2. Remove the 4 bolts <B>.

    3. Remove the 3 bolts <C>.

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

    5. Disconnect each connector.

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

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


    1. A01KT3Q

      Using a clip remover, remove the clip.

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

    3. A01KTA9C01
      A01KRLR Bolt
      A01KR22 Screw
      A01KSJJ Nut

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

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


    1. A01KRIY

      Using a clip remover, remove the clip.

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

    3. A01KS6QC01
      A01KRLR Bolt
      A01KR22 Screw
      A01KSJJ Nut

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

  19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

      A01KTRL

  20. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Disconnect the drain cooler hose.

      A01KS0FC01
      A01KR22 Bolt A01KSJJ Nut

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

  21. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A01KR10

      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.

  22. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01KRAL

      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.

  23. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. for Cold Area:


      1. A01KTUH

        Remove the screw.

      2. Disengage each clamp and disconnect the wire harness.

    2. Disconnect the connector.

      A01KSTH

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

  24. REMOVE HEATER COVER (except Cold Area)


    1. A01KSRX

      Disengage the 4 claws to remove the heater cover.

  25. REMOVE ASPIRATOR


    1. A01KSYB

      Disengage the 2 claws to remove the aspirator.

  26. REMOVE CONSOLE MOUNTING BRACKET LH


    1. A01KSAN

      Remove the screw and console mounting bracket LH.

  27. REMOVE CONSOLE MOUNTING BRACKET RH


    1. A01KTPO

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

  28. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A01KT4A

      Disconnect the connector.

    2. Remove the screw.

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

      A01KS3V

  29. REMOVE DRAIN COOLER HOSE


    1. A01KTIH

      Remove the drain cooler hose.

  30. REMOVE AIR CONDITIONING HARNESS ASSEMBLY


    1. Disengage each clamp.

      A01KSAPC01
      *A for Dual Type - -

    2. Disconnect each connector.

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