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 up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

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

  2. REMOVE FRONT SEAT ASSEMBLY


    1. for LH Side: Click here

    2. for RH Side:

      Tech Tips

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

  3. REMOVE ENGINE ROOM SIDE COVER


    1. A019LQM

      Remove the 4 clips.

    2. Disengage the guide and remove the engine room side cover.

  4. REMOVE ENGINE ROOM SIDE COVER LH


    1. A019K5V

      Remove the 4 clips.

    2. Disengage the guide and remove the engine room side cover LH.

  5. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A019MCL

      Remove the 6 clips and cool air intake duct seal.

  6. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH


    1. A019ND4E01
      Text in Illustration
      *1 Hood to Cowl Top Seal

      Disengage the clip and the hood to cowl top seal to the front fender top reinforcement sub-assembly LH.

    2. A019O73

      Remove the clip.

    3. Disengage the 3 clips and 2 guides, and remove the front fender top reinforcement sub-assembly LH.

  7. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

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

  8. REMOVE FRONT FENDER TO COWL SIDE SEAL LH


    1. A019KT9E01
      Text in Illustration
      *1 Double-Sided Tape

      Disengage the 2 claws and remove the front fender to cowl side seal LH.

  9. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

    Tech Tips

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

  10. REMOVE FRONT WIPER ARM HEAD CAP


    1. A019LRLE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, disengage the 3 claws and remove the front wiper arm head cap.

      Tech Tips

      Tape the screwdriver tip before use.

  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A019P9E

      Remove the nut and the front wiper arm and blade assembly LH.

  12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A019M64

      Remove the 2 nuts and the front wiper arm and blade assembly RH.

  13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the 2 clips.

      A019LS7E01

    2. Disengage the 6 claws and guide <A>.

    3. Disengage the 10 guides and pull out the cowl top ventilator louver sub-assembly as shown in the illustration.

  14. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A019NAG

      w/o Deicer:


      1. Disconnect the connector.

      2. Disengage the clamp.

    3. A019JXV

      w/ Deicer:


      1. Disconnect the 2 connectors.

      2. Disengage the clamp.

    4. A019K93

      Remove the 5 bolts and the wind shield wiper motor and link assembly as shown in the illustration.

      Note

      Be careful not to damage the windshield when removing the windshield wiper motor and link assembly.

  15. REMOVE FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension)


    1. A019N7O

      Remove the 3 nuts and the front shock absorber cap.

  16. REMOVE FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

    Tech Tips

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

  17. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  18. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A019OF9

      Disengage the 6 clamps and separate the engine wire harness.

    2. A019OF4

      Remove the bolt and slide the hook connector.

    3. Disconnect the suction pipe assembly.

    4. Remove the O-ring from the suction pipe assembly.

      Note

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

  19. 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.

  20. DISCONNECT OUTLET HEATER WATER HOSE


    1. A019PLP

      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 outlet heater water hose.

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

  21. DISCONNECT INLET HEATER WATER HOSE


    1. A019M1Y

      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.

  22. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  23. REMOVE STEERING POST ASSEMBLY

    Click here

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


    1. A019LCF

      Disconnect the 2 connectors.

    2. A019NWNE01

      Disengage the 2 claws as shown in the illustration and disconnect the 2 connectors (A).

    3. Disconnect the 4 connectors (B).

    4. A019KOC

      Remove the 2 nuts.

    5. A019LWE

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

    6. A019P66

      Disengage the 2 claws and release the connector lock as shown in the illustration.

    7. A019KX6

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

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


    1. A019LQ1

      Disconnect the 3 connectors.

    2. A019LFHE02

      Disengage the 2 claws as shown in the illustration and disconnect the 2 connectors (A).

    3. Disconnect the connector (B).

    4. A019K06

      Remove the bolt and nut.

    5. A019KXU

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

    6. A019P66

      Disengage the 2 claws and release the connector lock as shown in the illustration.

    7. A019KX6

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

  26. REMOVE POWER STEERING ECU ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  27. REMOVE TURN SIGNAL FLASHER ASSEMBLY


    1. A019NEI

      Disengage the clamp.

    2. Disconnect the connector and remove the turn signal flasher assembly.

  28. REMOVE CLEARANCE WARNING BUZZER


    1. A019LR7

      Disconnect the connector.

    2. Disengage the clamp and remove the clearance warning buzzer.

  29. REMOVE ECU INTEGRATION BOX


    1. A019NXV

      Remove the bolt, 2 nuts and ECU integration box.

  30. REMOVE REAR NO. 2 AIR DUCT


    1. A019L89E01

      Disengage the 2 clamps and fastener.

    2. Disengage the claw and turn back the floor carpet as shown in the illustration.

      Text in Illustration
      *1 Clamp
      *2 Fastener
    3. A019MAX

      Remove the clip.

    4. Disengage the claw and remove the rear No. 2 air duct.

  31. REMOVE REAR NO. 1 AIR DUCT


    1. A019O53

      Disengage the clamp.

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

  32. REMOVE FRONT FLOOR CAUTION PLATE COVER


    1. A019KIU

      Disengage the claw.

    2. A019KR8

      Disengage the guide and remove the frame number cover as shown in the illustration.

  33. REMOVE REAR NO. 4 AIR DUCT


    1. A019NV1E01

      Disengage the 2 clamps and fastener.

    2. Disengage the claw and turn back the floor carpet as shown in the illustration.

      Text in Illustration
      *1 Clamp
      *2 Fastener
    3. A019O3K

      Remove the clip.

    4. Disengage the claw and remove the rear No. 4 air duct.

  34. REMOVE REAR NO. 3 AIR DUCT


    1. A019OHP

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

  35. REMOVE CENTER HEATER TO REGISTER SUB DUCT


    1. A019O22

      Remove the 3 clips and center heater to register sub duct.

  36. REMOVE NO. 5 INSTRUMENT PANEL BRACKET


    1. A019L15

      Remove the 2 No. 5 instrument panel brackets.

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


    1. A019PB6E01
      Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut

      Disengage each clamp.

    2. Remove the screw.

    3. Remove the 2 bolts, 2 nuts and No. 1 instrument panel brace sub-assembly.

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


    1. A019PDYE01
      Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut

      Disengage each clamp.

    2. Remove the screw.

    3. Remove the 2 bolts, 2 nuts and No. 2 instrument panel brace sub-assembly.

  39. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY


    1. Disengage each clamp.

    2. Disconnect each connector.

    3. Remove the bolt and disconnect the earth wire.

      A019PK6E01
      Text in Illustration
      *1 Bolt *2 Earth wire

    4. Disengage each clamp.

    5. Disconnect the connector.

    6. Disconnect the blower motor connector.

    7. Disconnect the 2 air conditioning ECU connectors.

    8. Remove the bolt and disconnect the earth wire.

    9. Remove the nut and disconnect the connector holder.

      A019LNKE01
      Text in Illustration
      *1 Blower motor connector *2 Air conditioning ECU connector
      *3 Nut *4 Connector holder
      *5 Bolt *6 Earth wire

    10. Remove the 2 bolts and 2 caps from the engine compartment side.

    11. Remove the nut.

    12. Disconnect the cooler drain hose.

      A019NVUE01
      Text in Illustration
      *1 Cap *2 Bolt
      *3 Nut *4 Cooler drain hose

    13. Remove the 5 instrument panel safety pad caps.

    14. Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts and the instrument panel reinforcement assembly with air conditioning unit assembly.

      A019MXAE01
      Text in Illustration
      *1 Instrument panel safety pad cap *2 "TORX" bolt

  40. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A019K0R

      Disengage the 4 claws and remove the No. 1 air duct sub-assembly.

  41. REMOVE AIR CONDITIONING UNIT ASSEMBLY


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

      A019JWY