AIR CONDITIONING UNIT REMOVAL

PROCEDURE

1. PRECAUTION

   Note:

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

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Cooler System)

   for HFC-134a (R134a):

   Click here

   for HFO-1234yf (R1234yf):

   Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 1ND-TV)

   Click here

4. REMOVE WATER GUARD PLATE LH (for 1ND-TV)

   for LHD:

   for Sedan:Click here

   for Hatchback, Wagon:Click here

   for RHD:

   for Sedan:Click here

   for Hatchback, Wagon:Click here

5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for 1ND-TV)

   for LHD:

   for Sedan:Click here

   for Hatchback, Wagon:Click here

   for RHD:

   for Sedan:Click here

   for Hatchback, Wagon:Click here

6. REMOVE OUTER COWL TOP PANEL (for 1ND-TV)

   for LHD:

   for Sedan:Click here

   for Hatchback, Wagon:Click here

   for RHD:

   for Sedan:Click here

   for Hatchback, Wagon:Click here

7. REMOVE COOLER CAP (w/o Cooler System)

   1. 

      Remove the bolt and cooler cap.

8. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Cooler System)

   1. w/o Sub-cool Accelerator:

      1. 

         Remove the bolt and rotate the hook connector as shown in the illustration.

      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.

9. DISCONNECT AIR CONDITIONER TUBE ASSEMBLY (w/ Cooler System)

   1. w/o Sub-cool Accelerator:

      1. 

         Disconnect the air conditioner tube assembly.

      2. Remove the O-ring from the air conditioner tube assembly.

         Note:

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

10. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Cooler System)

    1. w/ Sub-cool Accelerator:

       1. 

          Remove the bolt and rotate the hook connector as shown in the illustration.

       2. 

          Disconnect the air conditioner tube and accessory assembly.

       3. Remove the 2 O-rings from the air conditioner tube and accessory assembly.

          Note:

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

11. DISCONNECT HEATER WATER OUTLET HOSE A

    1. 

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

       Note:

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

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

12. DISCONNECT HEATER WATER INLET HOSE A

    1. 

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

       Note:

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

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

13. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    for Sedan:Click here

    for Hatchback, Wagon:Click here

14. REMOVE STEERING COLUMN ASSEMBLY

    Click here

15. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for LHD)

    Click here

16. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for RHD)

    Click here

17. REMOVE DRIVING SUPPORT ECU ASSEMBLY (for 1ND-TV)

    w/ Cruise Control System:

    Click here

18. REMOVE TELEMATICS TRANSCEIVER (w/ Manual (SOS) Switch)

    Click here

19. REMOVE REAR NO. 1 AIR DUCT (for Cold Area)

    

    1. Disengage the 8 claws and remove the rear No. 1 air duct.

20. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)

    1. 

       Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.

21. REMOVE DEFROSTER NOZZLE ASSEMBLY

    1. 

       Disengage the 6 claws and remove the defroster nozzle assembly.

22. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE

    

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

23. DISCONNECT INSTRUMENT PANEL WIRE (for LHD)

    1. for Cold Area:

       1. 

          Disconnect the 2 connectors.

    2. Remove the 2 bolts <A> and disconnect the ground portion of the wiring harness protector cover and earth wire.

       

       *A	w/ ECU Integration Box RH	*B	w/o Radio Receiver
       *C	for Automatic Air Conditioning System	*D	for Manual Air Conditioning System
       *a	Ground Portion of the Wiring Harness Protector Cover	*b	Earth Wire
       *c	Guide	*d	Clamp
       	Bolt <A>		Bolt <B>
       	Bolt <C>		Connector

    3. Remove the 5 bolts <B>.

    4. w/ ECU Integration Box RH:

       1. Remove the 3 bolts <C>.

       2. Disengage the guide and disconnect the ECU integration box RH.

    5. Disconnect each connector.

    6. Disengage each clamp and disconnect the instrument panel wire.

24. DISCONNECT INSTRUMENT PANEL WIRE (for RHD)

    1. for Cold Area:

       1. 

          Disconnect the 2 connectors.

    2. Remove the 2 bolts <A> and disconnect the ground portion of the wiring harness protector cover and earth wire.

       

       *A	w/ ECU Integration Box RH	*B	w/o Radio Receiver
       *C	for Manual Air Conditioning System	*D	for Automatic Air Conditioning System
       *a	Ground Portion of the Wiring Harness Protector Cover	*b	Earth Wire
       *c	Guide	*d	Clamp
       	Bolt <A>		Bolt <B>
       	Bolt <C>		Connector

    3. Remove the 4 bolts <B>.

    4. w/ ECU Integration Box RH:

       1. Remove the 3 bolts <C>.

       2. Disengage the guide and disconnect the ECU integration box RH.

    5. Disconnect each connector.

    6. Disengage each clamp and disconnect the instrument panel wire.

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

    1. 

       Using a clip remover, remove the clip.

    2. Turn back the front floor carpet assembly as shown in the illustration.

    3. 

       	Bolt
       	Screw
       	Nut

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

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

    1. 

       Using a clip remover, remove the clip.

    2. Turn back the front floor carpet assembly as shown in the illustration.

    3. 

       	Bolt
       	Screw
       	Nut

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

27. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

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

       

28. REMOVE AIR CONDITIONER UNIT ASSEMBLY

    1. Disconnect the drain cooler hose.

       

       Bolt

       Nut

    2. Remove the bolt, nut and air conditioner unit assembly.

29. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY

    1. 

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

       Note:

       If any of the claws of the No. 2 air duct sub-assembly have been cracked or deformed during removal, make sure to replace the air duct with a new one. Failure to do so may cause the No. 2 air duct sub-assembly to fall off or noise to occur.

30. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY

    1. 

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

       Note:

       If any of the claws of the No. 3 air duct sub-assembly have been cracked or deformed during removal, make sure to replace the air duct with a new one. Failure to do so may cause the No. 3 air duct sub-assembly to fall off or noise to occur.

31. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY

    1. for Cold Area:

       1. 

          Remove the screw.

       2. Disengage each clamp and disconnect the wire harness.

    2. for Automatic Air Conditioning System:

       1. Disconnect the connector.

          

          *A

          for Automatic Air Conditioning System

          -

          -

    3. Remove the 3 screws and air conditioning radiator assembly.

32. REMOVE HEATER COVER (except Cold Area)

    1. 

       Disengage the 4 claws to remove the heater cover.

33. REMOVE ASPIRATOR PIPE (w/o Cooler System)

    1. 

       Disengage the 2 claws to remove the aspirator pipe.

34. REMOVE ASPIRATOR (for Automatic Air Conditioning System)

    1. for LHD:

       1. 

          Disengage the 2 claws to remove the aspirator.

    2. for RHD:

       1. 

          Disengage the clamp.

       2. Disengage the 2 claws to remove the aspirator.

35. REMOVE CONSOLE MOUNTING BRACKET LH

    1. 

       Remove the screw and console mounting bracket LH.

36. REMOVE CONSOLE MOUNTING BRACKET RH

    1. 

       Disengage the 2 claws to remove the console mounting bracket RH.

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

    1. 

       Remove the screw.

    2. Remove the air conditioning amplifier assembly as shown in the illustration.

       

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

    1. 

       Disconnect the connector.

    2. Remove the screw.

    3. Remove the air conditioning amplifier assembly as shown in the illustration.

       

39. REMOVE DRAIN COOLER HOSE

    1. 

       Remove the drain cooler hose.

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

    1. Disengage each clamp.

       

       *A

       for Dual Type

       -

       -

    2. Disconnect each connector.

    3. Remove the air conditioning harness assembly as shown in the illustration.