FRONT AIR CONDITIONING UNIT REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

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

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Click here

  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  4. REMOVE FRONT WIPER ARM HEAD CAP

    Click here

  5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

    Click here

  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

    Click here

  7. REMOVE FRONT FENDER TO COWL SIDE SEAL LH

    Click here

  8. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

    Click here

  9. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  10. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 2GR-FE)

    Click here

  11. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2GR-FE)

    for LHD:

    Click here

    for RHD:

    Click here

  12. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A002AHT

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

    2. A00277Q

      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.

  13. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A002AFP

      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.

  14. DISCONNECT OUTLET HEATER WATER HOSE


    1. A002AEM

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

      Note


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

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

  15. DISCONNECT INLET HEATER WATER HOSE


    1. A002B6P

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

      Note


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

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

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

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure as for the LH side.

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

    Tech Tips

    Use the same procedure as for the LH side.

  20. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  21. REMOVE STEERING POST ASSEMBLY

    Click here

  22. REMOVE ECU INTEGRATION BOX RH (for LHD)

    w/ ECU Integration Box:

    Click here

  23. REMOVE ECU INTEGRATION BOX LH (for RHD)

    w/ ECU Integration Box:

    Click here

  24. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  25. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    for LHD:

    Click here

    for RHD:

    Click here

  26. REMOVE WIRE HARNESS CLAMP BRACKET (for LHD)


    1. A0029B7

      Disengage the 3 clamps.

    2. Remove the nut and wire harness clamp bracket.

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


    1. A0028ZG

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

  28. REMOVE REAR NO. 2 AIR DUCT


    1. A0029ONC01
      B004057 Fastener

      Disengage 4 guides and 2 fasteners, and turn back the front floor carpet assembly as shown in the illustration.

    2. A002CED

      Remove the clip and rear No. 2 air duct.

  29. REMOVE REAR NO. 1 AIR DUCT


    1. A002760

      Disengage the clamp to disconnect the wire harness.

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

  30. REMOVE REAR NO. 4 AIR DUCT


    1. A002CEYC01
      B004057 Fastener

      Disengage the 4 guides and fastener, and turn back the front floor carpet assembly as shown in the illustration.

    2. A002C3Z

      Remove the clip and rear No. 4 air duct.

  31. REMOVE REAR NO. 3 AIR DUCT


    1. A002CHG

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

  32. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY

    for U660E Automatic Transmission / Transaxle:

    Click here

    for U660F Automatic Transmission / Transaxle:

    Click here

    for U760E Automatic Transmission / Transaxle:

    Click here

  33. REMOVE SHIFT LEVER SUPPORT


    1. Disconnect each connector.

    2. B003ZBUC01
      B003ZIE Nut
      B003Z8F Bolt

      Disengage each clamp.

    3. Remove the 2 nuts, 4 bolts and shift lever support.

  34. REMOVE WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

    Click here

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


    1. A0029XDC01
      *a Earth Wire

      Disengage each clamp.

    2. Remove the bolt and disconnect the earth wire.

    3. A002915C01
      B003ZIE Bolt
      B003Z8F Screw
      B003ZMU Nut

      Remove the 2 bolts, screw, 2 nuts and No. 1 instrument panel brace sub-assembly.

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


    1. A0026V4

      Disengage each clamp.

    2. A002A00C01
      B003ZIE Bolt
      B003Z8F Screw
      B003ZMU Nut

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

  37. REMOVE INSTRUMENT PANEL SAFETY PAD CAP


    1. A00279PC01
      *A for LH Side
      *B for RH Side
      B004057 Protective Tape

      Put protective tape around the 4 instrument panel safety pad caps.

    2. Using a screwdriver, remove the 4 instrument panel safety pad caps.

  38. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    Note


    • Be sure to support the air conditioning unit assembly when removing it. Failure to do so may cause the bracket of the air conditioning unit assembly to break.

    • When disassembling the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. for LHD:


      1. Remove the 4 bolts and disconnect the 4 earth wires.

        A0027R0C01
        *a Earth Wire - -

      2. Disconnect each connector.

      3. Disengage each clamp.

    2. for RHD:


      1. Remove the 3 bolts and disconnect the 3 earth wires.

        A002CCYC01
        *a Earth Wire - -

      2. Disconnect each connector.

      3. Disengage each clamp.

    3. A00299V

      Remove the 2 hole plugs.

    4. A0029TP

      Remove the 2 bolts.

    5. A0028L6

      Disengage the claw and disconnect the drain cooler hose from the piping clamp.

    6. A002BD8C01
      *A for LH Side
      *B for RH Side

      Remove the 2 hole plugs.

    7. Disconnect the drain cooler hose.

      A002CDTC01
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Vehicle Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
      B003Z8F Nut B003ZMU Bolt

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

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

      A00289U

  39. REMOVE AIR CONDITIONING UNIT ASSEMBLY


    1. Remove the 3 bolts.

      A002AJF

    2. Disengage the 2 claws to remove the air conditioning unit assembly from the instrument panel reinforcement assembly.