AIR CONDITIONING UNIT REMOVAL


  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 power switch off.

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

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for RHD)

    Click here

  3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003Z14

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  4. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003WN3

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  5. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A003YWK

      Remove the 2 bolts and cowl body mounting reinforcement RH.

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A003X05

      Disengage the clamp and separate the wire harness.

    2. A003X62

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003ZGV

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  7. SEPARATE RESERVOIR TUBE ASSEMBLY (for RHD)


    1. A003VUB

      Remove the 2 bolts, nut and separate the reservoir tube assembly.

  8. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A003VBA

      Remove the bolt and slide the hook connector.

    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.

  9. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Disconnect the air conditioning tube and accessory assembly.

    2. Remove the O-ring from the air conditioning tube and accessory assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  10. DISCONNECT OUTLET HEATER WATER HOSE


    1. A003W4R

      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 heater water hose.

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

  11. DISCONNECT INLET HEATER WATER HOSE


    1. A003WE2

      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.

  12. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

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  13. REMOVE STOP LIGHT SWITCH ASSEMBLY


    1. A003X5G

      Disconnect the connector.

    2. A003XB7

      Turn the stop light switch assembly counterclockwise and remove it.

  14. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER

  15. REMOVE BRAKE PEDAL RETURN SPRING (for RHD)


    1. A003VLV

      Remove the brake pedal return spring from the brake pedal support assembly and push rod pin.

  16. REMOVE PUSH ROD PIN (for RHD)


    1. A003VFK

      Remove the clip and push rod pin to separate the brake pedal support assembly from the push rod clevis.

  17. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY (for RHD)


    1. A003X0O

      Remove the bolt and separate the brake pedal support assembly from the instrument panel reinforcement.

    2. A003Y28

      Disengage the clamp.

    3. A003ZFT

      Remove the 4 nuts and brake pedal support assembly.

    4. A003VNB

      Remove the nut from the brake pedal support assembly.

  18. REMOVE POWER STEERING ECU ASSEMBLY (for LHD)


    1. A003ZT2E01
      Text in Illustration
      *1 Lock of the Lock Lever
      *2 Lock Lever

      Disconnect the connector from the power steering ECU assembly.

      Tech Tips

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

    2. A003X77

      Disconnect the 3 connectors from the power steering ECU assembly.

    3. A003WYB

      Remove the bolt, 2 nuts and power steering ECU assembly.

  19. REMOVE POWER STEERING ECU ASSEMBLY (for RHD)


    1. A003VG2E01
      Text in Illustration
      *1 Lock of the Lock Lever
      *2 Lock Lever

      Disconnect the connector from the power steering ECU assembly.

      Tech Tips

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

    2. A003Y1O

      Disconnect the 3 connectors from the power steering ECU assembly.

    3. A003XOK

      Remove the bolt, 2 nuts and power steering ECU assembly.

  20. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  21. REMOVE HORN BUTTON ASSEMBLY

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  22. REMOVE STEERING WHEEL ASSEMBLY


    1. A003Z6ZE01
      Text in Illustration
      *a Matchmark

      Remove the steering wheel assembly set nut.

    2. Put matchmarks on the steering wheel assembly and steering main shaft.

    3. Disconnect the connectors from the spiral cable and steering wheel assembly.

    4. A003X3RE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the steering wheel assembly.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09955-04071 )

      Note

      Apply a small amount of grease to the threads and tip of SST (09953-05020) before use.

  23. REMOVE STEERING COLUMN COVER

    Note

    Removing the steering column cover in the incorrect order will cause the parts to break.


    1. A003ZEW

      Remove the 2 screws.

    2. A003ZVR

      Push the right and left sides of the steering column cover (lower side) to disengage the 4 claws.

    3. A003XDK

      Insert fingers into the opening of the tilt lever of the steering column cover (lower side) to disengage the 2 claws and remove the steering column cover (lower side).

      Tech Tips

      Spread the claws to disengage them.

    4. A003WUH

      Disengage the 4 clips and 2 guides from the steering column cover (upper side).

    5. A003XIV

      Disengage the 2 claws to remove the steering column cover (upper side).

  24. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY

    Note


    • Do not replace the spiral cable with the auxiliary battery connected and the power switch on (IG).

    • Do not rotate the spiral cable without the steering wheel with the auxiliary battery connected and the power switch on (IG).

    • Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor.

    • Do not remove the steering sensor from the spiral cable.


    1. Disconnect the connectors from the turn signal switch assembly with spiral cable sub-assembly.

    2. A003WO8E01
      Text in Illustration
      *1 Clamp
      *2 Claw

      Using pliers, expand the clamp.

    3. While holding the clamp expanded, raise the claw using a screwdriver to disengage it, and then remove the turn signal switch assembly with spiral cable sub-assembly from the steering post assembly.

  25. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY (for LHD)


    1. A003Z47

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

  26. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A003ZML

      Disengage the 2 claws and remove the rear No. 2 air duct sub-assembly.

  27. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A003ZTF

      Turn back the floor carpet.

    2. Remove the 2 clips and column hole cover silencer sheet.

  28. REMOVE STEERING POST ASSEMBLY (for LHD)


    1. A003ZT2E01
      Text in Illustration
      *1 Lock of Lock Lever
      *2 Lock Lever

      Disconnect the connector from the power steering ECU assembly.

      Tech Tips

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

    2. A003YQ7

      Disconnect the connector from the power steering ECU assembly.

    3. A003VPO

      Disengage the 2 wire harness clamps.

    4. Disengage the wire harness clamps from the steering post assembly.

    5. A003YFE

      Remove the bolt, 2 nuts and steering post assembly.

  29. REMOVE STEERING POST ASSEMBLY (for RHD)


    1. A003YF9

      Disengage the 2 wire harness clamps.

    2. Disengage the wire harness clamps from the steering post assembly.

    3. A003WON

      Remove the bolt, 2 nuts and steering post assembly.

  30. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A003YG6E01
      Text in Illustration
      *a Matchmark

      Put matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft.

    2. Remove the bolt.

    3. Separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.

  31. REMOVE WINDSHIELD WIPER RELAY ASSEMBLY


    1. A003X33

      Disconnect the connector.

    2. Remove the bolt and windshield wiper relay assembly.

  32. REMOVE CENTER INSTRUMENT PANEL REINFORCEMENT SUB-ASSEMBLY


    1. A003YLI

      Remove the bolt, nut and center instrument panel reinforcement sub-assembly.

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


    1. A003XQAE01
      Text in Illustration
      *1 Earth Wire

      Disconnect each connector.

    2. Disengage each clamp.

    3. Remove the bolt and disconnect the earth wire.

    4. A003XNE

      Remove the screw.

    5. Remove the bolt, nut and No. 1 instrument panel brace sub-assembly.

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


    1. A003WUOE01
      Text in Illustration
      *1 Earth Wire

      Disengage each clamp.

    2. Remove the bolt and disconnect the earth wire.

    3. A003WJL

      Remove the screw.

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

  35. REMOVE REAR NO. 2 AIR DUCT


    1. A003Z2P

      Disengage the 6 claws and remove the rear No. 2 air duct.

  36. REMOVE REAR NO. 1 AIR DUCT


    1. A003XCQ

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

  37. REMOVE NO. 2 HEATER TO REGISTER DUCT


    1. A003VNK

      Remove the 3 clips and No. 2 heater to register duct.

  38. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A003W8H

      Disengage each clamp.

    2. A003X6W

      Remove the 2 clips.

    3. A003XNQ

      Disengage the 6 claws and remove the lower defroster nozzle assembly.

  39. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE


    1. A003ZSR

      Remove the 2 bolts.

    2. Disengage the guide and remove the instrument panel reinforcement.

  40. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for LHD)


    1. A003Z3R

      Disconnect each connector.

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

    3. A003WBL

      Disengage the 2 clamps and disconnect the wire harness.

    4. A003W1D

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

    5. A003YDE

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

    6. A003YPG

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

    7. Remove the instrument panel junction block assembly.

  41. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for RHD)


    1. Disconnect each connector.

    2. A003V48

      Disengage the clamp.

    3. Remove the bolt and nut, and disconnect the instrument panel junction block assembly.

    4. A003XA9

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

    5. A003ZF4

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

    6. A003Z46

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

    7. Remove the instrument panel junction block assembly.

  42. REMOVE ECU INTEGRATION BOX RH (for LHD)


    1. A003XH1

      Disconnect each connector.

    2. Disengage the clamp and disconnect the wire harness.

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

  43. REMOVE ECU INTEGRATION BOX LH (for RHD)


    1. A003YA0

      Disconnect each connector.

    2. Disengage the clamp and disconnect the wire harness.

    3. Remove the bolt, nut and ECU integration box LH.

  44. REMOVE ECU INTEGRATION BOX RH (for RHD)


    1. Disconnect each connector.

    2. A003YT8

      Disengage the clamp.

    3. Remove the bolt.

    4. Remove the nut and ECU integration box RH.

  45. REMOVE INSTRUMENT PANEL REINFORCEMENT


    1. Disconnect the center airbag sensor connectors from the center airbag sensor assembly as shown in the illustration.

      Note

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

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

    3. Remove the 3 bolts.

    4. w/ PTC Heater:


      1. A003ZS6

        Disconnect the 2 connectors.

    5. Disconnect each connector.

    6. Disengage each clamp.

      A003XEBE01
      Text in Illustration
      *1 Center Airbag Sensor Connector *2 Earth wire

    7. for LHD:


      1. A003Y93

        Remove the bolt and separate the brake pedal support assembly from the instrument panel reinforcement.

    8. Remove the 8 bolts and instrument panel reinforcement.

      A003XXE

  46. 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 brackets of the air conditioning unit assembly to break.

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


    1. A003ZWI

      Disengage the clamp.

    2. Disengage the cooler drain hose.

    3. Remove the bolt, nut and air conditioning unit assembly.