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AIR CONDITIONING UNIT REMOVAL

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Tip:

  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

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  1. Click here

    PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. Click here

    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. Click here

    DRAIN ENGINE COOLANT (for 1AD-FTV)


    1. Loosen the radiator drain cock plug.

      Tip:

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

    2. A01IUC4E01

      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.

      Table 1. Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Radiator Drain Cock Plug - -
  4. Click here

    DRAIN ENGINE COOLANT (for 2AD-FHV)


    1. Loosen the radiator drain cock plug.

      Tip:

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

    2. A01IUC4E01

      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.

      Table 2. Text in Illustration
      *1 Radiator Reservoir Cap *2 Air Release Plug
      *3 Radiator Drain Cock Plug - -
  5. Click here

    DRAIN ENGINE COOLANT (for 1ZR-FAE)


    1. Loosen the radiator drain cock plug.

      Tip:

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

    2. A01INZOE01

      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.

      Table 3. Text in Illustration
      *1 Radiator Reservoir Cap *2 Radiator Drain Cock Plug
  6. Click here

    DRAIN ENGINE COOLANT (for 2ZR-FAE)


    1. Loosen the radiator drain cock plug.

      Tip:

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

    2. A01INZOE01

      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.

      Table 4. Text in Illustration
      *1 Radiator Reservoir Cap *2 Radiator Drain Cock Plug
  7. Click here

    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. Click here

    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. Click here

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


    1. A01INMI

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear of the No. 1 engine cover. Continue to raise the No. 1 engine cover to detach the 3 clips on the front and side of the No. 1 engine cover and remove the No. 1 engine cover.

      Note:

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

  10. Click here

    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. Click here

    REMOVE FRONT WIPER ARM HEAD CAP


    1. A01IRPA

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

      Tip:

      • Tape the screwdriver tip before use.

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

  12. Click here

    REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A01INFE

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

  13. Click here

    REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. A01IT06

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

  14. Click here

    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. Click here

    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. Click here

    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. Click here

    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. Click here

    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. Click here

    REMOVE COWL TOP OUTER PANEL


    1. A01IO5B

      Remove the 9 bolts and outer cowl top panel.

  20. Click here

    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. 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.

  22. Click here

    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. Click here

    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. Click here

    REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY


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

  25. Click here

    REMOVE STEERING COLUMN ASSEMBLY


    1. Remove the steering column assembly (Click here).

  26. Click here

    REMOVE FRONT DOOR SCUFF PLATE LH


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

  27. Click here

    REMOVE COWL SIDE TRIM BOARD LH


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

  28. Click here

    REMOVE FRONT DOOR SCUFF PLATE RH

    Tip:

    Use the same procedure described for the LH side.

  29. Click here

    REMOVE COWL SIDE TRIM BOARD RH

    Tip:

    Use the same procedure described for the LH side.

  30. Click here

    REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY


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

  31. Click here

    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. Click here

    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. Click here

    REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01IRTH

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

  34. Click here

    REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A01IR2J

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

  35. Click here

    REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE


    1. A01IUAH

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

  36. Click here

    REMOVE INSTRUMENT PANEL BRACE ASSEMBLY


    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.

      Table 5. Text in Illustration
      *1 except Manual Transaxle
  37. Click here

    REMOVE REAR NO. 2 AIR DUCT


    1. A01IP49

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

  38. Click here

    REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Remove the 2 bolts and ground wire.

    2. A01IPVD

      Detach each clamp and disconnect the wire harness.

    3. Disconnect each connector.

    4. Detach each clamp.

    5. A01ITI6E01

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

      Table 6. Text in Illustration
      *1 except Manual Transaxle *2 w/ PTC Heater
    6. A01INN7

      Remove the 8 bolts and instrument panel reinforcement assembly.

  39. Click here

    REMOVE AIR CONDITIONING UNIT


    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. Click here

    REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A01IUQM

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

  41. Click here

    REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01IR2A

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

  42. Click here

    REMOVE BLOWER ASSEMBLY


    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.