AIR CONDITIONING UNIT REMOVAL

Note

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


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Operate the cooler compressor under the conditions shown below:

      Item Condition Indicator
      Operating Time 3 minutes or more -
      Temperature setting Max cool -
      Blower speed High A01G9SU
      Engine Idling -
      A/C switch On A01G57E

      This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

      Tech Tips

      It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock, etc.

    3. Stop the engine.

    4. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

      Tech Tips

      Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  4. DISCONNECT HEATER OUTLET WATER HOSE


    1. A01G4KT

      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. A01G7J4

      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 PIPE SUB-ASSEMBLY


    1. A01G6FN

      Remove the bolt and rotate the hook connector.

    2. A01G6A9

      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.

  7. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A01G7B0

      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

    Click here

  9. REMOVE AUDIO AMPLIFIER COVER


    1. A01G7J8

      Using a clip remover, remove the clip.

    2. Disengage the 2 claws and remove the audio amplifier cover.

  10. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET


    1. A01G6BH

      Disconnect each connector.

    2. Remove the bolt.

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

  11. REMOVE FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  12. REMOVE AUDIO AMPLIFIER COVER (w/ Telematics Transceiver)


    1. A01G54W

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

  13. REMOVE TELEMATICS TRANSCEIVER WITH MAYDAY BATTERY (w/ Telematics Transceiver)


    1. A01G7B6

      Remove the bolt and disengage the 2 guides.

    2. Pull out the telematics transceiver with mayday battery in the direction indicated by the arrow shown in the illustration.

    3. A01G6O1

      Disconnect each connector.

  14. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  15. REMOVE STEERING POST ASSEMBLY

    Click here

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


    1. A01G93W

      Remove the nut.

    2. Disconnect the connector and remove the windshield wiper relay assembly.

  17. REMOVE DRIVING SUPPORT ECU ASSEMBLY (w/ Dynamic Radar Cruise Control System)

    for RHD: Click here

  18. REMOVE SEAT BELT CONTROL ECU (w/ Pre-crash Safety System)


    1. Disconnect each connector.

    2. A01G85H

      Remove the bolt and seat belt control ECU.

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


    1. for LHD:


      1. A01G5DH

        Disconnect each connector.

      2. A01G5GJ

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

      3. A01G5K1

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

      4. A01G46O

        Remove the bolt and 2 nuts, and pull out the instrument panel junction block assembly with main body ECU.

      5. A01G4QF

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

      6. A01G9EE

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

      7. A01G98Y

        Disengage the claw and disconnect the connector as shown in the illustration to remove the instrument panel junction block assembly with main body ECU.

    2. for RHD:


      1. A01G97W

        Disconnect each connector.

      2. A01G6LD

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

      3. A01G81N

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

      4. A01G5FC

        Remove the bolt and nut, and pull out the instrument panel junction block assembly with main body ECU.

      5. A01G6S0

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

      6. A01G7NP

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

      7. A01G649

        Disengage the claw and disconnect the connector as shown in the illustration to remove the instrument panel junction block assembly with main body ECU.

  20. REMOVE WIRING HARNESS CLAMP BRACKET (for RHD)


    1. A01G4Q9

      Remove the nut.

    2. Disengage the claw to remove the wiring harness clamp bracket.

  21. REMOVE ECU INTEGRATION BOX RH

    for LHD: Click here

    for RHD: Click here

  22. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A01G6H6

      Disconnect the 3 connectors.

    2. Remove the 2 screws.

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

  23. REMOVE FLOOR CARPET HOOK


    1. A01G55ZE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disengage the 6 guides.

    2. A01G7CPE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

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

  24. REMOVE REAR AIR DUCT GUIDE LH


    1. A01G9VC

      Disengage the guide.

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

    3. A01G46X

      Disengage the 4 claws to remove the rear air duct guide LH.

  25. REMOVE REAR NO. 2 AIR DUCT


    1. A01G5SJ

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

  26. REMOVE FLOOR CARPET BRACKET LH


    1. A01G47K

      Remove the 2 clips.

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

  27. REMOVE FRONT FLOOR CAUTION PLATE COVER


    1. A01G8ZB

      Using a moulding remover, disengage the claw and guide, and remove the front floor caution plate cover.

  28. REMOVE REAR AIR DUCT GUIDE RH


    1. A01G881

      Disengage the guide.

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

    3. A01G5KR

      Disengage the 4 claws to remove the rear air duct guide RH.

  29. REMOVE REAR NO. 1 AIR DUCT


    1. A01G90E

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

  30. REMOVE FLOOR CARPET BRACKET RH


    1. A01G5G8

      Remove the 2 clips.

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

  31. REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET (w/ PTC Heater)

    for U660E Automatic Transmission / Transaxle: Click here

    for U760E Automatic Transmission / Transaxle: Click here

  32. REMOVE NO. 1 CONSOLE BOX DUCT


    1. A01G6ZL

      Remove the clip and No. 1 console box duct.

  33. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. A01G6GD

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

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


    1. A01G7WU

      Disconnect the connector.

    2. Disengage the clamp.

    3. A01G6YVE02
      Text in Illustration
      *a Screw
      *b Bolt
      *c Nut

      Remove the screw.

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

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


    1. A01G60RE02
      Text in Illustration
      *a Earth Wire

      Remove the bolt and disconnect the earth wire.

    2. Disconnect the connector.

    3. Disengage each clamp.

    4. A01G8OEE02
      Text in Illustration
      *a Screw
      *b Bolt
      *c Nut

      Remove the screw.

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

  36. REMOVE NO. 1 HEATER TO REGISTER DUCT


    1. A01G4LZ

      Disengage the clamp.

    2. Using a clip remover, remove the 3 clips and No. 1 heater to register duct.

  37. REMOVE INSTRUMENT PANEL SAFETY PAD CAP


    1. A01G9C1E02
      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.

  38. 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. A01G5W6

      Disengage each clamp.

    2. w/ Telematics Transceiver:


      1. A01G84V

        Disengage each clamp.

    3. A01G7ZF

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

    4. Disconnect the connector from the airbag sensor assembly as shown in the illustration.

      A01G8I2E01
      Text in Illustration
      *1 Airbag Sensor Assembly - -

      Note

      When disconnecting any airbag connector, take care not to damage the airbag wire harness.

    5. Disconnect each connector.

    6. Disengage each clamp.

    7. w/ PTC Heater:


      1. for U660E Automatic Transmission / Transaxle:


        1. Remove the lower shift lever assembly Click here.

        2. Remove the shift lever support Click here.

      2. for U760E Automatic Transmission / Transaxle:


        1. Remove the lower shift lever assembly Click here.

        2. Remove the shift lever support Click here.

      3. A01G5MA

        Remove the bolt.

      4. Disconnect the connector.

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

      A01G8GSE02
      Text in Illustration
      *a Retainer *b Protective Tape

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

      A01G57V

    10. for LHD:


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

        A01G9VNE03
        Text in Illustration
        *a Connector Holder *b Protector
        *c Earth Wire *d Nut
        *e Bolt - -

      2. Remove the nut and disconnect the protector.

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

      4. Disconnect the connector.

      5. Disengage each clamp.

    11. for RHD:


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

        A01G8TEE01
        Text in Illustration
        *a Connector Holder *b Earth Wire
        *c Nut *d Bolt

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

      3. Disconnect the connector.

      4. Disengage each clamp.

    12. A01G4QY

      Remove the 2 hole plugs.

    13. A01G892

      Remove the 2 bolts.

    14. Disconnect the drain cooler hose.

      A01G9OFE02
      Text in Illustration
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4

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

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

      A01G6LT

  39. REMOVE AIR CONDITIONING UNIT ASSEMBLY


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

      A01G6OG

  40. REMOVE BLOWER ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  41. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for LHD)


    1. Disconnect each connector.

      A01G6CLE02
      Text in Illustration
      *A for 3 Zone Type - -

    2. Disengage each clamp and remove the air conditioning harness assembly.

  42. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for RHD)


    1. Disconnect each connector.

      A01G9K0E01
      Text in Illustration
      *A for 3 Zone Type - -

    2. Disengage each clamp and remove the air conditioning harness assembly.

  43. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A01G9QQ

      Disengage the 2 claws and 2 guides to remove the No. 6 heater to register duct assembly as shown in the illustration.

  44. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01G4Y8

      Disengage the 2 claws and guide to remove the No. 1 air duct sub-assembly as shown in the illustration.

  45. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A01G760

      Disengage the 2 claws and guide to remove the No. 4 air duct sub-assembly as shown in the illustration.

  46. REMOVE HEATER PACKING


    1. A01G502

      Remove the heater packing as shown in the illustration.

  47. REMOVE COOLER THERMISTOR HOSE


    1. A01G8H6

      Disengage the clamp and remove the cooler thermistor hose.

  48. REMOVE ASPIRATOR PIPE


    1. A01G8DY

      Disengage the 2 claws and remove the aspirator pipe.

  49. REMOVE DRAIN COOLER HOSE


    1. A01G6F8

      Remove the drain cooler hose.