AIR CONDITIONING UNIT (for Manual Air Conditioning System) REMOVAL

Tech Tips


  • Use the same procedure for LHD and RHD vehicles.

  • The procedure listed below is for LHD vehicles.


  1. REMOVE FRONT COVER BUMPER ABSORBER


    1. A005U7U

      Remove the 4 screws and 2 bolts.

      Tech Tips

      Pull down the fender liner so that the front lower bumper absorber can be removed in the next step.

    2. A005TN1

      Remove the 3 screws, 8 bolts and front lower bumper absorber.

  2. REMOVE NO. 1 ENGINE UNDER COVER


    1. for 1AZ-FE:

      Remove the No. 1 engine under cover Click here.

    2. for 1ZR-FAE:

      Remove the No. 1 engine under cover Click here.

    3. for 2ZR-FAE:

      Remove the No. 1 engine under cover Click here.

    4. for 3ZR-FAE:

      Remove the No. 1 engine under cover Click here.

    5. for 3ZR-FE:

      Remove the No. 1 engine under cover Click here.

  3. REMOVE NO. 1 ENGINE COVER


    1. for 1AZ-FE:

      Remove the No. 1 engine cover Click here.

    2. for ZR Series Engine:

      Remove the No. 1 engine cover Click here.

  4. REMOVE ENGINE ROOM SIDE COVER


    1. A005RE1

      Remove the clip and engine room side cover.

  5. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A005SU5

      Remove the 8 clips and radiator support opening cover.

  6. DRAIN ENGINE COOLANT


    1. for 1AZ-FE:

      Drain the engine coolant Click here.

    2. for 1ZR-FAE:

      Drain the engine coolant Click here.

    3. for 2ZR-FAE:

      Drain the engine coolant Click here.

    4. for 3ZR-FAE:

      Drain the engine coolant Click here.

    5. for 3ZR-FE:

      Drain the engine coolant Click here.

  7. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

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

  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

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

    Note


    • w/ Navigation System for HDD:

      After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  9. REMOVE FRONT WIPER MOTOR AND BRACKET


    1. Remove the front wiper motor and bracket Click here.

  10. REMOVE COWL TOP OUTER PANEL


    1. A00DSK0

      Remove the 9 bolts and outer cowl top panel.

  11. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY


    1. A00DQJR

      Remove the bolt.

    2. Detach the plate as shown in the illustration.

    3. A00DPR3E03
      Text in Illustration
      *1 Disconnect tube by hand

      Disconnect the air conditioning tube assembly.

      Note


      • Do not use a screwdriver or similar tool to disconnect the tube.

      • Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

    4. Remove the 2 O-rings from the air conditioning tube assembly.

  12. DISCONNECT HEATER WATER OUTLET HOSE A

    A00DR5W

    1. Using pliers, grip the claws of the clip and slide the clip.

    2. Disconnect the heater water outlet hose.

  13. DISCONNECT HEATER WATER INLET HOSE A

    A00DPYS

    1. Using pliers, grip the claws of the clip and slide the clip.

    2. Disconnect the heater water inlet hose.

  14. REMOVE FRONT DOOR SCUFF PLATE LH

    A00DQKA

    1. Detach the 8 claws and 2 clips, and remove the front door scuff plate.

  15. REMOVE FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  16. REMOVE COWL SIDE TRIM BOARD LH

    A00DTRI

    1. Detach the clip, claw and guide, and remove the cowl side trim board.

  17. REMOVE COWL SIDE TRIM BOARD RH

    Tech Tips

    Use the same procedure described for the LH side.

  18. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Remove the upper instrument panel Click here.

  19. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Remove the lower instrument panel Click here.

  20. REMOVE REAR NO. 3 AIR DUCT

    A00DPVO

    1. Remove the clip.

    2. Fold back the floor carpet.

    3. A00DS10

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

  21. REMOVE REAR NO. 2 AIR DUCT

    A00DU5U

    1. Remove the clip.

    2. Fold back the floor carpet.

    3. A00DT3K

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

  22. REMOVE REAR NO. 1 AIR DUCT

    A00DS51

    1. Detach the 4 claws and remove the rear No. 1 air duct.

  23. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (for Driver Side)

    A00DRWP

    1. Detach the 2 claws and remove the duct.

  24. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (for Front Passenger Side)

    A00DT2E

    1. Detach the 2 claws and remove the duct.

  25. REMOVE STEERING COLUMN ASSEMBLY


    1. for Manual Tilt and Manual Telescopic Steering Column:

      Remove the steering column Click here.

    2. for Power Tilt and Power Telescopic Steering Column:

      Remove the steering column Click here.

  26. REMOVE DEFROSTER NOZZLE ASSEMBLY

    A00DUZZ

    1. w/ Navigation System:

      Remove the navigation antenna assembly.


      1. Remove the 2 screws.

      2. Detach the claw and remove the navigation antenna assembly.

    2. A00DSS8

      Detach the 4 claws and remove the defroster nozzle assembly.

  27. REMOVE AIR DUCT ASSEMBLY

    A00DQY3

    1. Remove the 2 nuts and duct.

  28. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE

    A00DPVK

    1. Remove the 2 bolts and brace.

  29. REMOVE POWER STEERING ECU ASSEMBLY

    A003BSO

    1. Detach the wire harness clamp from the power steering ECU.

    2. Disconnect the connector from the power steering ECU.


      1. As shown in the illustration, pull out the lock of the lock lever and turn the lock lever to disconnect the connector.

    3. A003EG6

      Disconnect the 3 connectors from the power steering ECU.

    4. A003DUL

      Remove the bolt, 2 nuts and power steering ECU.

  30. REMOVE MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY)

    A00DRMC

    1. Disconnect the 3 connectors.

    2. Remove the 2 bolts and main body ECU.

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

    A00DS3C

    1. Detach the 4 clamps.

    2. Remove the nut, 2 bolts and brace.

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

    A00DRDI

    1. Detach the clamp.

    2. Remove the nut, 2 bolts and brace.

  33. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Disconnect the clamps, connectors and wire harness.

    2. Remove the instrument panel reinforcement.


      1. for Manual Transaxle:

        Remove the bolt from the clutch pedal.

      2. Remove the bolts, screws and instrument panel reinforcement.

        A00DTRYE03
        Text in Illustration
        *1 for Manual Transaxle *2 w/ PTC Heater

  34. REMOVE AIR CONDITIONING UNIT

    A00DTIP

    1. Disconnect the drain cooler hose.

    2. Remove the nut, bolt and air conditioning unit.