AIR CONDITIONING UNIT REMOVAL

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. 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.

  3. DRAIN ENGINE COOLANT (for 1AD-FTV)


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap and air release plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      Tech Tips

      The plug is on the backside of the generator on the EGR cooler side.

      A01IU4LE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Cylinder Block Drain Cock Plug (Type A) *4 Cylinder Block Drain Cock Plug (Type B)
      *5 Radiator Drain Cock Plug - -

  4. DRAIN ENGINE COOLANT (for 2AD-FHV)


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap and air release plug, while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    3. Loosen the cylinder block drain cock plug. Then drain the coolant from the engine.

      Tech Tips

      The plug is on the backside of the generator on the EGR cooler side.

      A01IU4LE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Cylinder Block Drain Cock Plug (Type A) *4 Cylinder Block Drain Cock Plug (Type B)
      *5 Radiator Drain Cock Plug - -

  5. DRAIN ENGINE COOLANT (for 1ZR-FAE)


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap while the engine and radiator are still hot.

      Pressurized, hot engine coolant and steam may be released and cause serious burns.

      A01INZOE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Radiator Drain Cock Plug

  6. DRAIN ENGINE COOLANT (for 2ZR-FAE)


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the radiator reservoir cap.

      CAUTION:

      Do not remove the radiator reservoir cap while the engine and radiator are still hot.

      Pressurized, hot engine coolant and steam may be released and cause serious burns.

      A01INZOE01
      Text in Illustration
      *1 Radiator Reservoir Cap *2 Radiator Drain Cock Plug

  7. 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.

  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

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

  9. REMOVE NO. 1 ENGINE COVER (for AD Series Engine)


    1. A01INMI

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  10. REMOVE NO. 2 CYLINDER HEAD COVER (for ZR Series Engine)


    1. A01IRS7

      Hold the rear of the cover and raise it to detach the 2 clips on the rear of the cover. Continue to raise the cover to detach the 2 clips on the front of the cover and remove the cover.

      Note

      Attempting to detach both front and rear clips at the same time may cause the cover to break.

  11. REMOVE FRONT WIPER ARM HEAD CAP


    1. A01IRPA

      Using a screwdriver, remove the front wiper arm head cap.

      Tech Tips


      • Tape the screwdriver tip before use.

      • Use the same procedure for all front wiper arm head caps.

  12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A01INFE

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

  13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A01IT06

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

  14. REMOVE HOOD TO COWL TOP SEAL


    1. A01IQHZ

      Using a clip remover, detach the 7 clips and 2 claws, and remove the hood to cowl top seal.

  15. REMOVE COWL TOP VENTILATOR LOUVER LH


    1. A01INVH

      Detach the 2 claws and 2 guides, and remove the center cowl top ventilator louver.

    2. A01ISIY

      Remove the clip.

    3. Detach the 6 claws and 5 guides, and remove the cowl top ventilator louver LH.

  16. REMOVE COWL TOP VENTILATOR LOUVER RH


    1. A01IUL4

      Remove the clip.

    2. Detach the 4 claws and 5 guides, and remove the cowl top ventilator louver RH.

  17. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01IQJZ

      Disconnect the connector. Then detach the clamp and remove the wire harness from the cowl top panel.

    2. A01ITHG

      Remove the 2 bolts.

    3. A01IO76

      Move the wiper cushion in the direction shown by the arrow in the illustration to detach the wiper cushion from the body and remove the wiper motor and link.

  18. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)


    1. A01ISZQ

      Detach the wire harness clamp and disconnect the sensor connector.

    2. Remove the bolt and sensor.

    3. Disconnect the 2 vacuum hoses.

  19. REMOVE COWL TOP OUTER PANEL


    1. A01IO5B

      Remove the 9 bolts and outer cowl top panel.

  20. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A01IRDN

      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.

  21. 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.

  22. DISCONNECT HEATER OUTLET WATER HOSE


    1. A01ISQI

      Using pliers, grip the claws of the clip, slide the clip and disconnect the heater outlet water hose.

      Note


      • Do not apply excessive force to the heater outlet water hose.

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

  23. DISCONNECT HEATER INLET WATER HOSE


    1. A01ISIH

      Using pliers, grip the claws of the clip, slide the clip and disconnect the heater inlet water hose.

      Note


      • Do not apply excessive force to the heater inlet water hose.

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

  24. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY


    1. Remove the instrument panel safety pad sub-assembly Click here.

  25. REMOVE STEERING COLUMN ASSEMBLY


    1. Remove the steering column assembly Click here.

  26. REMOVE FRONT DOOR SCUFF PLATE LH

    A01IPG9

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

  27. REMOVE COWL SIDE TRIM BOARD LH

    A01ISRD

    1. Detach the 2 clips and guide, and remove the cowl side trim board.

  28. REMOVE FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  29. REMOVE COWL SIDE TRIM BOARD RH

    Tech Tips

    Use the same procedure described for the LH side.

  30. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Remove the lower instrument panel sub-assembly Click here.

  31. REMOVE REAR NO. 3 AIR DUCT


    1. A01IUMD

      Remove the clip.

    2. Fold back the floor carpet.

    3. A01IS35

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

  32. REMOVE REAR NO. 1 AIR DUCT


    1. A01IP64

      Remove the clip.

    2. Fold back the floor carpet.

    3. A01IRJL

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

  33. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01IRTH

      Remove the 2 nuts and No. 1 air duct sub-assembly.

  34. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A01IR2J

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

  35. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE


    1. A01IUAH

      Remove the 2 bolts and center instrument panel to cowl brace.

  36. REMOVE INSTRUMENT PANEL BRACE ASSEMBLY

    A01IQ6QE01
    Text in Illustration
    *1 except Manual Transaxle

    1. Disconnect the connector.

    2. Detach each clamp.

    3. Remove the 2 screws.

    4. Remove the 3 bolts, 2 nuts and instrument panel brace assembly.

  37. REMOVE REAR NO. 2 AIR DUCT


    1. A01IP49

      Detach the 4 claws and remove the rear No. 2 air duct.

  38. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Remove the 2 bolts and ground wire.

    2. Detach each clamp and disconnect the wire harness.

      A01IPVD

    3. Disconnect each connector.

    4. Detach each clamp.

    5. Remove each bolt, and disconnect the wire harness and junction block.

      A01ITI6E01
      Text in Illustration
      *1 except Manual Transaxle *2 w/ PTC Heater

    6. Remove the 8 bolts and instrument panel reinforcement assembly.

      A01INN7

  39. REMOVE AIR CONDITIONING UNIT

    A01IRO7

    1. Disconnect the drain cooler hose.

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

      Note


      • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.

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

  40. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A01IUQM

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

  41. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01IR2A

      Detach the 2 claws and remove the No. 3 air duct sub-assembly.

  42. REMOVE BLOWER ASSEMBLY

    A01INPL

    1. w/ PTC Heater:

      Remove the screw.

    2. A01IT3H

      w/ PTC Heater:

      Detach the 3 clamps.

    3. A01IPHJ

      Disconnect the connector.

    4. Remove the 3 screws and blower assembly.