FRONT AIR CONDITIONING UNIT REMOVAL

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for RHD vehicles.

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed or replaced during the front air conditioning unit removal/installation are shown below.

Necessary Procedures after parts removed / installed / replaced
Replacement Part or Procedure Necessary Procedures Effects / Inoperative when not Performed Link
Disconnect cable from negative battery terminal

    w/ Power Back Door System:

  • Reset back door close position

 Power back door system

Click here

CAUTION:

Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing.

B003QQS

Click here

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DRAIN ENGINE COOLANT (for Automatic Air Conditioning System, Manual Air Conditioning System)


    1. for 1GR-FE:

      Click here

    2. for 1KD-FTV:

      Click here

    3. for 2KD-FTV:

      Click here

    4. for 1GD-FTV:

      Click here

    5. for 2GD-FTV:

      Click here

    6. for 2TR-FE:

      Click here

    7. for 5L-E:

      Click here

  3. REMOVE NO. 2 WIRING HARNESS PROTECTOR (for GD Series Engine, LHD)


    1. B003QA2

      Remove the 2 nuts.

    2. Detach the claw and remove the No. 2 wiring harness protector.

  4. REMOVE VACUUM HOSE ASSEMBLY (for GD Series Engine, LHD)


    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the vacuum hose.

      Note

      Do not apply excessive force to the vacuum hose.

    2. Detach the claw.

    3. Remove the 2 bolts and remove the vacuum hose assembly.

      B003JWN

  5. REMOVE NO. 2 WIRING HARNESS PROTECTOR (for GD Series Engine, RHD)


    1. B003JK8

      Remove the 2 nuts.

    2. Detach the claw, guide and remove the No. 2 wiring harness protector.

  6. REMOVE VACUUM HOSE ASSEMBLY (for GD Series Engine, RHD)


    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the vacuum hose.

      Note

      Do not apply excessive force to the vacuum hose.

    2. Detach the claw.

    3. Remove the 2 bolts and remove the vacuum hose assembly.

      B003MNA

  7. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (for 1GD-FTV, 2GD-FTV)


    1. B003KEZ

      Remove the bolt and disconnect the air conditioner tube and accessory assembly.

    2. 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 the entry of moisture and foreign matter.

  8. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (except 1GD-FTV, 2GD-FTV)


    1. B003NWIC01
      B003OFB Remove in this Direction

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

    2. B003LY9

      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.

  9. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (except 1GD-FTV, 2GD-FTV)


    1. B003JK1

      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 the entry of moisture and foreign matter.

  10. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (except 1GD-FTV, 2GD-FTV, w/ Sub-cool Accelerator)


    1. B003KLGC02
      B003OFB Remove in this Direction

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

    2. B003PV6

      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 the entry of moisture and foreign matter.

  11. DISCONNECT HEATER WATER OUTLET HOSE (for Automatic Air Conditioning System, Manual Air Conditioning System)


    1. B003OIC

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

      Note


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

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

  12. DISCONNECT HEATER WATER INLET HOSE (for Automatic Air Conditioning System, Manual Air Conditioning System)


    1. B003PTE

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

      Note


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

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

  13. REMOVE HEATER GROMMET (for Automatic Air Conditioning System, Manual Air Conditioning System)

    B003KST

    1. Detach the claw and remove the heater grommet.

  14. REMOVE FRONT SEAT ASSEMBLY LH


    1. for Manual Seat:

      Click here

    2. for Power Seat:

      Click here

  15. REMOVE FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  16. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  17. REMOVE NO. 2 AIR DUCT


    1. B003L6S

      Remove the bolt.

    2. Detach the claw and remove the No. 2 air duct.

      Note


      • When removing, do not crack or deform the lower heater case of the air conditioning radiator assembly.

      • If the No. 2 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace it with a new one.

  18. REMOVE NO. 1 AIR DUCT


    1. B003NDR

      Detach the claw and remove the No. 1 air duct.

      Note


      • When removing, do not crack or deform the lower heater case of the air conditioning radiator assembly.

      • If the No. 1 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace it with a new one.

  19. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  20. REMOVE FRONT DOOR SCUFF PLATE LH

    Click here

  21. REMOVE COWL SIDE TRIM BOARD LH

    Click here

  22. REMOVE FRONT DOOR SCUFF PLATE RH

    Click here

  23. REMOVE COWL SIDE TRIM BOARD RH

    Click here

  24. REMOVE REAR DOOR SCUFF PLATE LH

    Click here

  25. REMOVE REAR DOOR SCUFF PLATE RH

    Click here

  26. REMOVE LOWER CENTER PILLAR GARNISH LH

    Click here

  27. REMOVE LOWER CENTER PILLAR GARNISH RH

    Click here

  28. REMOVE FRONT FLOOR CARPET ASSEMBLY


    1. for RHD:

      Remove the 5 clips.

      B003L9LC01
      B003KT0 Fastener B003OFB Remove in this Direction

    2. for LHD:

      Remove the 6 clips.

      B003SCIC02
      B003KT0 Fastener B003OFB Remove in this Direction

    3. Detach each fastener.

    4. Detach the guide and fold back the front floor carpet assembly as shown in the illustration.

  29. REMOVE NO. 1 INSTRUMENT PANEL INNER BRACKET COVER LH (for LHD)

    B003O9P

    1. Remove the 3 clips and No. 1 instrument panel inner bracket cover LH

  30. REMOVE NO. 3 DASH PANEL INSULATOR PAD


    1. B003NOYC01
      B003OFB Remove in this Direction

      Remove the No. 3 dash panel insulator pad as shown in the illustration.

  31. REMOVE NO. 2 DASH PANEL INSULATOR PAD


    1. B003RMKC01
      B003OFB Remove in this Direction

      Remove the No. 2 dash panel insulator pad as shown in the illustration.

  32. REMOVE NO. 4 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003JBS

      Detach the claw and remove the No. 4 rear air duct.

  33. REMOVE NO. 5 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003K6P

      Detach the claw and remove the No. 5 rear air duct.

  34. REMOVE NO. 2 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003K6O

      Detach the claw and remove the No. 2 rear air duct.

  35. REMOVE NO. 3 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003QA4

      Detach the claw and remove the No. 3 rear air duct.

  36. REMOVE NO. 1 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003NEK

      Remove the 2 clips and remove the No. 1 rear air duct.

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


    1. B003LOOC01
      B003R2S Nut
      B003LF2 Bolt
      B003QHB Screw

      Detach the clamp.

    2. Remove the nut, bolt, 4 screws and No. 1 instrument panel brace sub-assembly.

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


    1. B003RJLC01
      B003R2S Nut
      B003LF2 Bolt
      B003QHB Screw

      Remove the nut, bolt, 3 screws and No. 2 instrument panel brace sub-assembly.

  39. DISCONNECT INSTRUMENT PANEL WIRE


    1. B003KPU

      for Automatic Air Conditioning System:


      1. Disconnect the connector.

      2. Detach the clamp.

    2. B003NY4

      for Manual Air Conditioning System:


      1. Disconnect the connector.

      2. Detach the clamp.

    3. Remove each bolt and each ground wire.

      B003N3JC01
      *A for Manual Air Conditioning System *B for Automatic Air Conditioning System
      *C w/ PTC Heater - -
      *1 Ground Wire - -

    4. Disconnect each connector and detach each clamp.

    5. Remove each bolt, nut and screw, and then disconnect the instrument panel wire.

  40. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

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


    1. B003JNHC01
      *A for Driver Side
      B003KT0 Protective Tape

      Put protective tape around the hole plug.

    2. Using a screwdriver with its tip wrapped with protective tape, remove the 2 hole plugs.

    3. for Automatic Transmission:

      Remove the 11 bolts.

      B003MJYC01
      *A for Manual Transmission - -
      B003R2S Bolt A B003LF2 Bolt B
      B003QHB Bolt C B003PQ8 Bolt D

    4. for Manual Transmission:

      Remove the 12 bolts.

  41. REMOVE DEFROSTER NOZZLE ASSEMBLY

    B003K3T

    1. Detach the claw and remove the defroster nozzle assembly.

  42. REMOVE AIR CONDITIONING UNIT ASSEMBLY

    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 assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. Disconnect the drain cooler hose.

      B003JJZ

    2. Remove the nut and air conditioning unit assembly and instrument panel reinforcement assembly.

  43. REMOVE NO. 3 AIR DUCT


    1. B003OK3

      Detach the claw and remove the No. 3 air duct.