AIR CONDITIONING UNIT REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

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

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. DRAIN ENGINE COOLANT

    Click here

  5. REMOVE WINDSHIELD WIPER LINK ASSEMBLY

    Click here

  6. REMOVE FRONT NO. 1 VENTILATOR SEAL

    Click here

  7. REMOVE FRONT AIR SHUTTER SEAL RH

    Click here

  8. REMOVE INNER COWL TOP TO COWL BRACE

    Click here

  9. REMOVE INNER COWL TOP REINFORCEMENT

    Click here

  10. REMOVE INSIDE COWL TOP CORNER PANEL LH

    Click here

  11. REMOVE OUTER COWL TOP PANEL

    Click here

  12. DISCONNECT INLET HEATER WATER HOSE A

    Click here

  13. DISCONNECT HEATER WATER HOSE OUTLET A

    Click here

  14. SEPARATE SUCTION TUBE SUB-ASSEMBLY


    1. A005GDE

      Remove the bolt.

    2. Turn the hook connector clockwise and disconnect the suction tube sub-assembly.

    3. Remove the O-ring from the suction tube sub-assembly.

      Note

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

  15. SEPARATE LIQUID TUBE SUB-ASSEMBLY


    1. A005LME

      Disconnect the liquid tube sub-assembly.

    2. Remove the O-ring from the liquid tube sub-assembly.

      Note

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

  16. REMOVE FRONT SEAT ASSEMBLY

    Click here

  17. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  18. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  19. REMOVE STEERING COLUMN ASSEMBLY (for LHD)

    Click here

  20. REMOVE STEERING COLUMN ASSEMBLY (for RHD)

    Click here

  21. REMOVE NO. 2 HEATER TO RESISTER DUCT


    1. A005MGT

      Disengage the 6 claws and remove the No. 2 heater to register duct.

  22. REMOVE CENTER HEATER TO REGISTER DUCT


    1. A005JGI

      Disengage the 2 claws and remove the center heater to register duct.

  23. REMOVE DEFROSTER NOZZLE ASSEMBLY


    1. A005LHT

      Disconnect the connector and 4 clamps and separate the instrument panel wire. (w/ Entry and Start System)

    2. A005HCJ

      Disconnect the connector and 3 clamps and separate the instrument panel wire. (w/ Automatic Light Control System)

    3. A005JNA

      Disengage the 5 claws and remove the defroster nozzle assembly.

  24. REMOVE REAR NO. 2 AIR DUCT (w/ Rear Air Duct)


    1. A005ILM

      Peel back the floor mats.

    2. A005LJT

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

  25. REMOVE REAR NO. 3 AIR DUCT (w/ Rear Air Duct)


    1. A005HJP

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

  26. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct)


    1. A005HNM

      Disengage the 3 claws and remove the rear No. 1 air duct.

  27. SEPARATE DRAIN COOLER HOSE


    1. A005KEP

      Separate the drain cooler hose.

  28. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for LHD)


    1. A005MEO

      Disconnect the connector.

    2. Disengage the 4 clamps.

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

  29. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for RHD)


    1. A005GYC

      Disconnect the connector.

    2. Disengage the 4 clamps.

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

  30. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for LHD)


    1. A005LC3

      Disengage the 2 clamps.

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

  31. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for RHD)


    1. A005I3S

      Disengage the 2 clamps.

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

  32. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

    Click here

  33. SEPARATE INSTRUMENT PANEL WIRE


    1. Disconnect the airbag sensor connector.

      Tech Tips

      Refer to SRS CONNECTORS Click here.

    2. Disconnect the wire harness from the air conditioning unit.


      1. for LHD with Manual Air Conditioning System:


        1. A005LUU

          Disconnect the 4 connectors and 4 clamps.

      2. for RHD with Manual Air Conditioning System:


        1. A005I5E

          Disconnect the 4 connectors and 6 clamps.

      3. for LHD with Automatic Air Conditioning System:


        1. A005GN1

          Disconnect the 3 connectors and 2 clamps.

      4. for RHD with Automatic Air Conditioning System:


        1. A005JIF

          Disconnect the 2 connectors and 4 clamps.

    3. A005L4A

      Remove the 3 bolts and disconnect the ground wire from the instrument panel reinforcement.

    4. Disconnect each connector and clamp from the instrument panel reinforcement (for LHD).

      A005HSE

    5. Remove the 4 bolts and separate the instrument panel wire.

    6. Disconnect the connector and clamp from the instrument panel reinforcement (for RHD).

      A005IQI

    7. Remove the 4 bolts and separate the instrument panel wire.

  34. REMOVE INSTRUMENT PANEL REINFORCEMENT (for LHD)

    A005INCE01
    Text in Illustration
    *A LHD - -
    A005GO2 Bolt A A005IBX Bolt B

    1. Remove the 3 bolts (bolt B) and separate the air conditioner unit assembly from the instrument panel reinforcement.

    2. Remove the 7 bolts (bolt A) and the instrument panel reinforcement.

  35. REMOVE INSTRUMENT PANEL REINFORCEMENT (for RHD)

    A005J9YE01
    Text in Illustration
    *A RHD - -
    A005GO2 Bolt A A005IBX Bolt B

    1. Remove the 3 bolts (bolt B) and separate the air conditioner unit assembly from the instrument panel reinforcement.

    2. Remove the 7 bolts (bolt A) and the instrument panel reinforcement.

  36. REMOVE AIR CONDITIONING UNIT ASSEMBLY


    1. A005GZK

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

      Text in Illustration
      A005GO2 Bolt
      A005IBX Nut

  37. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)


    1. A005KX7

      Disconnect the 4 connectors and 9 clamps, and then remove the air conditioning harness (for LHD).

    2. A005JEH

      Disconnect the 5 connectors and 7 clamps, and then remove the air conditioning harness (for RHD).

  38. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. A005LA7

      Remove the 3 screws and the air conditioning radiator assembly.

  39. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (for Manual Air Conditioning System)

    Click here

  40. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (for Automatic Air Conditioning System)

    Click here

  41. REMOVE COOLER AIR HOSE (for Automatic Air Conditioning System)


    1. A005IMR

      Remove the cooler air hose.