AIR CONDITIONING UNIT REMOVAL

Note

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

  1. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM

    1. Turn the A/C switch on.

    2. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.

    3. Turn the ignition switch off.

    4. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

    1. Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.

      A011RPR

    2. Remove the 10 bolts and front outer cowl top panel sub-assembly.

      A011UOV

  4. DISCONNECT HEATER OUTLET WATER HOSE

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

      A011UZE

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

      A011V5B

      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 HOSE SUB-ASSEMBLY (for TMMK Made)

    1. Remove the bolt, and slide the hook connector.

      A011V8U

    2. 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.

  7. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made)

    1. Remove the bolt, and slide the hook connector.

      A011V8U

    2. 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.

  8. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

    1. 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.

  9. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat)

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  10. REMOVE FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat)

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  11. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat)

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  12. REMOVE FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat)

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  13. REMOVE AUDIO AMPLIFIER COVER (for 10 Speakers)

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

      A011R6Q

  14. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers)

    1. Remove the bolt and disconnect the ground wire.

      A011UVH

    2. Disconnect each connector.

    3. Disengage the clamp.

    4. Remove the bolt.

      A011V49

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

  15. REMOVE FRONT SEAT ASSEMBLY RH (for TMMK Made Manual Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  16. REMOVE FRONT SEAT ASSEMBLY RH (for TMMK Made Power Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  17. REMOVE FRONT SEAT ASSEMBLY RH (for SIA Made Manual Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  18. REMOVE FRONT SEAT ASSEMBLY RH (for SIA Made Power Seat)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  19. REMOVE AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch)

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

      A011UV5

  20. REMOVE DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch)

    1. Disconnect each connector.

      A011UKC

    2. Disengage the 3 clamps.

    3. Remove the bolt.

      A011RS2

    4. Disengage the 2 guides and remove the DCM (telematics transceiver) with back-up battery.

  21. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

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  22. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

    CAUTION:

    When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward.

    1. Check that the ignition switch is off.

    2. Check that the cable is disconnected from the negative (-) battery terminal.

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. Remove the 4 bolts.

      A011RH8

    4. Disengage the 2 claws to disconnect the DLC3.

    5. Disengage the 2 hooks to remove the lower No. 1 instrument panel airbag assembly.

      A011T0V

      Note

      When removing the lower No. 1 instrument panel airbag assembly, do not pull the airbag wire harness.

    6. Using a screwdriver with the tip wrapped with protective tape, release the airbag connector lock.

      A011S0YE01
      Text in Illustration
      *1 Protective Tape
      *2 Airbag Connector
      *3 Airbag Connector Lock

    7. Disconnect the airbag connector to remove the lower No. 1 instrument panel airbag assembly.

      Note

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

  23. REMOVE STEERING COLUMN ASSEMBLY

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  24. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

    1. Disconnect the 5 connectors.

      A011USO

    2. Remove the bolt and 2 nuts, and disconnect the instrument panel junction block assembly.

      A011UT3

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

      A011UQ5

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

      A011SCV

    5. Disengage the claw and disconnect the connector as shown in the illustration to remove the instrument panel junction block assembly.

      A011TXH

  25. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH)

    1. w/ ECU Integration Box RH:

      1. Disengage the 2 claws and remove the certification ECU (smart key ECU assembly).

        A011S53

    2. w/o ECU Integration Box RH:

      1. Disconnect each connector.

      2. Remove the bolt, nut and certification ECU (smart key ECU assembly).

        A011V1V

  26. REMOVE ECU INTEGRATION BOX RH (w/ ECU Integration Box RH)

    1. Disconnect each connector and disengage the clamp.

      A011UJ2

    2. Remove the bolt, 2 nuts and the ECU integration box RH.

  27. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

    1. Disconnect each connector.

    2. Remove the 2 screws.

      A011RNJ

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

  28. REMOVE FLOOR CARPET HOOK

    1. Disengage the 6 guides.

      A011QUYE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

    2. Disengage the 6 claws and remove the 6 floor carpet hooks.

      A011U2SE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

  29. DISCONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY

    1. Remove the screw.

      A011RHP

    2. Disengage the guide to disconnect the fuel lid lock open lever sub-assembly as shown in the illustration.

      A011TLD

  30. REMOVE REAR NO. 4 AIR DUCT

    1. Disengage the guide.

      A011S9R

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

    3. Disengage the 4 claws to remove the rear No. 4 air duct.

      A011RNZ

  31. REMOVE FLOOR CARPET BRACKET LH

    1. Remove the 2 clips.

      A011SC4

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

  32. REMOVE REAR NO. 3 AIR DUCT

    1. Disengage the 2 claws to remove the rear No. 3 air duct.

      A011SX1

  33. REMOVE REAR NO. 2 AIR DUCT

    1. Disengage the guide.

      A011UWN

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

    3. Disengage the 4 claws to remove the rear No. 2 air duct.

      A011T4U

  34. REMOVE FLOOR CARPET BRACKET RH

    1. Remove the 2 clips.

      A011TH6

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

  35. REMOVE REAR NO. 1 AIR DUCT

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

      A011U9C

  36. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct)

    1. Remove the clip and the No. 1 console box duct.

      A011SDP

  37. REMOVE INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

    1. Disconnect each connector.

      A011T26E01
      Text in Illustration
      *1 Earth Wire

    2. Disengage each clamp.

    3. Disconnect the connector.

    4. Remove the bolt and disconnect the earth wire.

    5. Remove the bolt and 2 nuts.

      A011SU8

    6. Remove the screw and the instrument panel to cowl brace sub-assembly.

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

    1. Disconnect the connector.

      A011TZSE01
      Text in Illustration
      *1 Earth Wire

    2. Disengage each clamp.

    3. Remove the bolt and disconnect the earth wire.

    4. Remove the bolt and 2 nuts.

      A011TK2

    5. Remove the screw and the No. 2 instrument panel brace sub-assembly.

  39. REMOVE INSTRUMENT PANEL SAFETY PAD CAP

    1. Put protective tape around the 5 instrument panel safety pad caps.

      A011TVME01
      Text in Illustration
      *A for LH Side
      *B for RH Side
      *1 Protective Tape

    2. Using a screwdriver, remove the 5 instrument panel safety pad caps.

  40. REMOVE FRONT LOWER PANEL PACKING

    1. Remove the 2 front lower panel packings as shown in the illustration.

      A011VBN

  41. 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. for 10 Speakers:

      1. Disengage the 3 clamps.

        A011RY7

    2. w/ Manual (SOS) Switch:

      1. Disengage the clamp.

        A011TVU

    3. Disengage 3 claw to open the 3 clamps.

      A011SFA

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

      A011S86E01
      Text in Illustration
      *A w/ Smart Key System
      *1 Airbag Sensor Assembly

      Note

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

    5. Disconnect the connector.

    6. Disengage each clamp.

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

      A011TCAE01
      Text in Illustration
      *1 Retainer *2 Protective Tape

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

      A011SHR

    9. Disengage each clamp.

      A011VADE01
      Text in Illustration
      *A for Power Tilt and Power Telescopic Steering Column - -
      *1 Earth Wire *2 Protector

    10. Disengage each clamp.

    11. for Power Tilt and Power Telescopic Steering Column:

      1. Remove the nut and disconnect the protector.

    12. Disconnect the connector.

      A011S8J

    13. Disengage each clamp.

    14. Remove the bolt and disconnect the earth wire.

      A011T3XE01
      Text in Illustration
      *1 Earth Wire *2 Connector Holder

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

    16. Disconnect the connector.

    17. Disengage each clamp.

    18. Remove the 2 bolts.

      A011SJ1

    19. Remove the 5 bolts and the nut as shown in the illustration.

      A011RA9E01
      Text in Illustration
      *1 Movable Collar *2 Body
      *3 Instrument Panel Reinforcement - -
      *a Step 1 *b Step 2
      *c Step 3 *d Step 4

    20. Disconnect the cooler drain hose.

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

      A011SMHE01
      Text in Illustration
      *1 w/ Engine Immobiliser System - -

    22. w/ Engine Immobiliser System:

      1. Disengage the claw and 2 guides and remove the transponder key ECU assembly as shown in the illustration.

  42. REMOVE TRANSPONDER KEY ECU ASSEMBLY (w/ Engine Immobiliser System)

    1. Disconnect the connector and remove the transponder key ECU assembly.

      A011U7B

  43. REMOVE AIR CONDITIONING UNIT ASSEMBLY

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

      A011RIB