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 (for HFC-134a(R134a))

    Click here

  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (for HFO-1234yf(R1234yf))

    Click here

  4. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)


    1. A01SFC4

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

    2. A01SFSU

      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.

  5. DISCONNECT AIR CONDITIONER TUBE ASSEMBLY (w/o Sub-cool Accelerator)


    1. A01SFB6

      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.

  6. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Sub-cool Accelerator)


    1. A01SFMB

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

    2. A01SFRK

      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.

  7. DISCONNECT HEATER WATER OUTLET HOSE A


    1. A01SFK1

      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.

  8. DISCONNECT HEATER WATER INLET HOSE A


    1. A01SFPU

      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.

  9. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

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  10. REMOVE STEERING COLUMN ASSEMBLY

    Click here

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

    Click here

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

    Click here

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

    A01SFQX

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

  14. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. A01SFOH

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

  15. REMOVE DEFROSTER NOZZLE ASSEMBLY


    1. A01SFUS

      Disengage the 6 claws and remove the defroster nozzle assembly.

  16. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE

    A01SFC5

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

  17. DISCONNECT INSTRUMENT PANEL WIRE (for LHD)


    1. for Cold Area:


      1. A01SFQT

        Disconnect the 2 connectors.

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

      A01SF8QC02
      *a Ground Portion of Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01SFBR Bolt <A> A01SFP4 Bolt <B>
      A01SFDP Bolt <C> A01SFIV 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.

  18. 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.

      A01SFU1C02
      *a Ground Portion of Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01SFBR Bolt <A> A01SFP4 Bolt <B>
      A01SFDP Bolt <C> A01SFIV 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.

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


    1. A01SFCA

      Using a clip remover, remove the clip.

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

    3. A01SFTZC01
      A01SFBR Bolt
      A01SFP4 Screw
      A01SFDP Nut

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

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


    1. A01SFT0

      Using a clip remover, remove the clip.

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

    3. A01SFCEC01
      A01SFBR Bolt
      A01SFP4 Screw
      A01SFDP Nut

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

  21. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

      A01SFML

  22. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Disconnect the drain cooler hose.

      A01SFMPC01
      A01SFP4 Bolt A01SFDP Nut

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

  23. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A01SFDU

      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.

  24. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01SFJR

      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.

  25. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. for Cold Area:


      1. A01SFSQ

        Remove the screw.

      2. Disengage each clamp and disconnect the wire harness.

    2. Disconnect the connector.

      A01SFR4

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

  26. REMOVE HEATER COVER (except Cold Area)


    1. A01SF7X

      Disengage the 4 claws to remove the heater cover.

  27. REMOVE ASPIRATOR


    1. A01SFUA

      Disengage the 2 claws to remove the aspirator.

  28. REMOVE CONSOLE MOUNTING BRACKET LH


    1. A01SFHI

      Remove the screw and console mounting bracket LH.

  29. REMOVE CONSOLE MOUNTING BRACKET RH


    1. A01SF8D

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

  30. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A01SFKP

      Disconnect the connector.

    2. Remove the screw.

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

      A01SFBP

  31. REMOVE DRAIN COOLER HOSE


    1. A01SFEB

      Remove the drain cooler hose.

  32. REMOVE AIR CONDITIONING HARNESS ASSEMBLY


    1. Disengage each clamp.

      A01SF8ZC01
      *A for Dual Type - -

    2. Disconnect each connector.

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