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AIR CONDITIONING UNIT REMOVAL

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Note:

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

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  1. Click here

    RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Turn the A/C switch on.

    2. Operate the A/C with the setting temperature at 25°C (77°F) and the blower level at LO for 10 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.

    3. Turn the power switch off.

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

  2. Click here

    REMOVE FRONT SEAT ASSEMBLY


    1. for LH Side: (Click here)

    2. for RH Side:

      Tip:

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

  3. Click here

    REMOVE ENGINE ROOM SIDE COVER


    1. A01NKI4

      Remove the 4 clips and engine room side cover.

  4. Click here

    REMOVE ENGINE ROOM SIDE COVER LH


    1. A01NJLS

      Remove the 4 clips.

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

  5. Click here

    REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01NJMT

      Remove the 6 clips and cool air intake duct seal.

  6. Click here

    REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH


    1. A01NIK8E01

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

      Table 1. Text in Illustration
      *1 Hood to Cowl Top Seal
    2. A01NIDU

      Remove the clip.

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

  7. Click here

    REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH

    Tip:

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

  8. Click here

    REMOVE FRONT FENDER TO COWL SIDE SEAL LH


    1. A01NL98E01

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

      Table 2. Text in Illustration
      *1 Double-sided Tape
  9. Click here

    REMOVE FRONT FENDER TO COWL SIDE SEAL RH

    Tip:

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

  10. Click here

    REMOVE FRONT WIPER ARM HEAD CAP


    1. A01NJXTE01

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

      Table 3. Text in Illustration
      *1 Protective Tape
      Tip:

      Tape the screwdriver tip before use.

  11. Click here

    REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A01NKD4

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

  12. Click here

    REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A01NJWH

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

  13. Click here

    REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. A01NKFFE01

      Remove the 2 clips.

    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. Click here

    REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


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

    2. A01NLD5

      w/o Deicer:


      1. Disconnect the connector.

      2. Disengage the clamp.

    3. A01NN8N

      w/ Deicer:


      1. Disconnect the 2 connectors.

      2. Disengage the clamp.

    4. A01NLNZ

      Remove the 5 bolts and the windshield wiper motor and link assembly.

      Note:

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

  15. Click here

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


    1. A01NN8K

      Remove the 3 nuts and front shock absorber cap.

  16. Click here

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

    Tip:

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

  17. Click here

    REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: (Click here)

    for RHD: (Click here)

  18. Click here

    DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A01NIQI

      Disengage the 6 clamps and separate the engine wire harness.

    2. A01NI45

      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. Click here

    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. Click here

    DISCONNECT OUTLET HEATER WATER HOSE


    1. A01NKI5

      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. Click here

    DISCONNECT INLET HEATER WATER HOSE


    1. A01NKAE

      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. Click here

    REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    (Click here)

  23. Click here

    REMOVE STEERING POST ASSEMBLY

    (Click here)

  24. Click here

    REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for LHD)


    1. A01NISQ

      Disconnect the 4 connectors.

    2. A01NL5RE02

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

    3. Disconnect the 4 connectors (B).

    4. A01NKVN

      Remove the 2 nuts.

    5. A01NIZ0

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

    6. A01NJJS

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

    7. A01NI7C

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

  25. Click here

    REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for RHD)


    1. A01NJ8Z

      Disconnect the 3 connectors.

    2. A01NK4YE02

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

    3. Disconnect the connector (B).

    4. A01NJCX

      Remove the bolt and nut.

    5. A01NJGF

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

    6. A01NJJS

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

    7. A01NI7C

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

  26. Click here

    REMOVE POWER STEERING ECU ASSEMBLY

    for LHD: (Click here)

    for RHD: (Click here)

  27. Click here

    REMOVE TURN SIGNAL FLASHER ASSEMBLY


    1. A01NJCO

      Disengage the clamp.

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

  28. Click here

    REMOVE CLEARANCE WARNING BUZZER


    1. A01NK3U

      Disconnect the connector.

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

  29. Click here

    REMOVE ECU INTEGRATION BOX


    1. A01NJ9O

      Remove the bolt, 2 nuts and ECU integration box.

  30. Click here

    REMOVE REAR NO. 2 AIR DUCT


    1. A01NJUQE01

      Disengage the 2 clamps and fastener.

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

      Table 4. Text in Illustration
      *1 Clamp
      *2 Fastener
    3. A01NIOM

      Remove the clip.

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

  31. Click here

    REMOVE REAR NO. 1 AIR DUCT


    1. A01NJBU

      Disengage the clamp.

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

  32. Click here

    REMOVE FRONT FLOOR CAUTION PLATE COVER


    1. A01NKBI

      Disengage the claw.

    2. A01NK7D

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

  33. Click here

    REMOVE REAR NO. 4 AIR DUCT


    1. A01NI3PE01

      Disengage the 2 clamps and fastener.

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

      Table 5. Text in Illustration
      *1 Clamp
      *2 Fastener
    3. A01NIEW

      Remove the clip.

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

  34. Click here

    REMOVE REAR NO. 3 AIR DUCT


    1. A01NKE4

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

  35. Click here

    REMOVE CENTER HEATER TO REGISTER SUB DUCT


    1. A01NL4H

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

  36. Click here

    REMOVE NO. 5 INSTRUMENT PANEL BRACKET


    1. A01NM1X

      Remove the 2 No. 5 instrument panel brackets.

  37. Click here

    REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. A01NJAIE01

      Disengage each clamp.

    2. Remove the screw.

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

      Table 6. Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut
  38. Click here

    REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. A01NMFWE01

      Disengage each clamp.

    2. Remove the screw.

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

      Table 7. Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut
  39. Click here

    REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY


    1. Disengage each clamp.

    2. Disconnect each connector.

    3. A01NLTLE01

      Remove the bolt and disconnect the earth wire.

      Table 8. 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. A01NIPQE01

      Remove the nut and disconnect the connector holder.

      Table 9. 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. A01NLR2E01

      Disconnect the cooler drain hose.

      Table 10. Text in Illustration
      *1 Cap *2 Bolt
      *3 Nut *4 Cooler Drain Hose

    13. Remove the 5 instrument panel safety pad caps.

    14. A01NI4XE01

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

      Table 11. Text in Illustration
      *1 Instrument Panel Safety Pad Cap *2 "TORX" Bolt
  40. Click here

    REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01NLT9

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

  41. Click here

    REMOVE AIR CONDITIONING UNIT ASSEMBLY


    1. A01NIWW

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