AIR CONDITIONING UNIT REMOVAL

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  3. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  4. DISCONNECT HEATER OUTLET WATER HOSE


    1. A01W4QJ

      Using pliers, grip the claws of the clip and slide the clip to 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.

  5. DISCONNECT HEATER INLET WATER HOSE


    1. A01W38G

      Using pliers, grip the claws of the clip and slide the clip to 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.

  6. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


    1. A01W2CR

      Remove the bolt and rotate the hook connector.

    2. A01VZGN

      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.

  7. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. A01W2J6

      Disconnect the air conditioner tube and accessory assembly.

    2. Remove the O-ring 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.

  8. REMOVE FRONT SEAT ASSEMBLY LH

    Click here

  9. REMOVE AUDIO AMPLIFIER COVER

    Click here

  10. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET

    Click here

  11. REMOVE FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  12. REMOVE AUDIO AMPLIFIER COVER (w/ Telematics Transceiver)

    Click here

  13. REMOVE TELEMATICS TRANSCEIVER (w/ Telematics Transceiver except G-BOOK)

    Click here

  14. REMOVE TELEMATICS TRANSCEIVER WITH MAYDAY BATTERY (w/ Telematics Transceiver for G-BOOK)

    Click here

  15. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  16. REMOVE STEERING POST ASSEMBLY

    Click here

  17. REMOVE WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

    Click here

  18. REMOVE DRIVING SUPPORT ECU ASSEMBLY (w/ Pre-crash Safety System)

    Click here

  19. REMOVE ENGINE STOP AND START ECU ASSEMBLY (w/ Stop and Start System)

    Click here

  20. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    Click here

  21. REMOVE WIRING HARNESS CLAMP BRACKET (for RHD)


    1. A01W17P

      Remove the nut.

    2. Disengage the claw to remove the wiring harness clamp bracket.

  22. REMOVE ECU INTEGRATION BOX RH

    for LHD: Click here

    for RHD: Click here

  23. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  24. REMOVE FLOOR CARPET HOOK


    1. A01W2GFE07
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disengage the 6 guides.

    2. A01W2CQE07
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disengage the 6 clamps and remove the 6 floor carpet hooks.

  25. REMOVE REAR AIR DUCT GUIDE LH


    1. A01W4NI

      Disengage the guide.

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

    3. A01W37H

      Disengage the 4 claws to remove the rear air duct guide LH.

  26. REMOVE REAR NO. 2 AIR DUCT


    1. A01W3TN

      Disengage the 2 claws to remove the rear No. 2 air duct.

  27. REMOVE FLOOR CARPET BRACKET LH


    1. A01VZIC

      Remove the 2 clips.

    2. Disengage the 2 guides to remove the floor carpet bracket LH.

  28. REMOVE FRONT FLOOR CAUTION PLATE COVER


    1. A01VZ8Q

      Using a moulding remover, disengage the claw and guide, and remove the front floor caution plate cover.

  29. REMOVE REAR AIR DUCT GUIDE RH


    1. A01W2J4

      Disengage the guide.

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

    3. A01W1D8

      Disengage the 4 claws to remove the rear air duct guide RH.

  30. REMOVE REAR NO. 1 AIR DUCT


    1. A01VZNV

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

  31. REMOVE FLOOR CARPET BRACKET RH


    1. A01W4ZD

      Remove the 2 clips.

    2. Disengage the 2 guides to remove the floor carpet bracket RH.

  32. REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET (w/ PTC Heater)

    for U660E Automatic Transmission / Transaxle: Click here

    for U760E Automatic Transmission / Transaxle: Click here

    for U761E Automatic Transmission / Transaxle: Click here

  33. REMOVE NO. 1 CONSOLE BOX DUCT


    1. A01W2EK

      Remove the clip and No. 1 console box duct.

  34. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. A01W54M

      Disconnect the connector and cooler thermistor hose, and remove the cooler (room temp. sensor) thermistor.

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


    1. A01W43P

      Disconnect the connector.

    2. Disengage the clamp.

    3. A01W4AIE07
      Text in Illustration
      *a Screw
      *b Bolt
      *c Nut

      Remove the screw.

    4. Remove the bolt, 2 nuts and No. 1 instrument panel brace sub-assembly.

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


    1. A01W4IBE07
      Text in Illustration
      *a Earth Wire

      Remove the bolt and disconnect the earth wire.

    2. Disconnect the connector.

    3. Disengage each clamp.

    4. A01W5RTE07
      Text in Illustration
      *a Screw
      *b Bolt
      *c Nut

      Remove the screw.

    5. Remove the bolt, 2 nuts and No. 2 instrument panel brace sub-assembly.

  37. REMOVE NO. 1 HEATER TO REGISTER DUCT


    1. A01W292

      Disengage the clamp.

    2. Using a clip remover, remove the 3 clips and No. 1 heater to register duct.

  38. REMOVE INSTRUMENT PANEL SAFETY PAD CAP


    1. A01W1UTE07
      Text in Illustration
      *A for LH Side
      *B for RH Side
      *a Protective Tape

      Put protective tape around the 5 instrument panel safety pad caps.

    2. Using a screwdriver, remove the 5 instrument panel safety pad caps.

  39. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH 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 disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. A01W2W3

      Disengage each clamp.

    2. w/ Telematics Transceiver:


      1. A01W3SV

        Disengage each clamp.

    3. A01VZIH

      Disengage the 3 claws to open the 3 clamps as shown in the illustration.

    4. Disconnect the connector from the airbag sensor assembly as shown in the illustration.

      A01W25FE01
      Text in Illustration
      *1 Airbag Sensor Assembly - -

      Note

      When disconnecting any airbag connector, take care not to damage the airbag wire harness.

    5. Disconnect each connector.

    6. Disengage each clamp.

    7. w/ PTC Heater:


      1. for U660E Automatic Transmission / Transaxle:


        1. Remove the lower shift lever assembly Click here.

        2. Remove the shift lever support Click here.

      2. for U760E Automatic Transmission / Transaxle:


        1. Remove the lower shift lever assembly Click here.

        2. Remove the shift lever support Click here.

      3. for U761E Automatic Transmission / Transaxle:


        1. Remove the lower shift lever assembly Click here

        2. Remove the shift lever support Click here

      4. A01VZWC

        Remove the bolt.

      5. Disconnect the connector.

    8. Using a screwdriver, disengage the 2 claws to unlock the retainer as shown in the illustration.

      A01W5ACE02
      Text in Illustration
      *a Retainer *b Protective Tape
    9. Disengage the claw and disconnect the airbag connector as shown in the illustration.

      A01W0ZW
    10. for LHD:


      1. Remove the 2 nuts and disconnect the connector holder.

        A01W4ASE04
        Text in Illustration
        *a Connector Holder *b Protector
        *c Earth Wire *d Nut
        *e Bolt - -
      2. Remove the nut and disconnect the protector.

      3. Remove the 4 bolts and disconnect the 4 earth wires.

      4. Disconnect the connector.

      5. Disengage each clamp.

    11. for RHD:


      1. Remove the 2 nuts and disconnect the connector holder.

        A01W42JE03
        Text in Illustration
        *a Connector Holder *b Earth Wire
        *c Nut *d Bolt
      2. Remove the 4 bolts and disconnect the 4 earth wires.

      3. Disconnect the connector.

      4. Disengage each clamp.

    12. A01W40D

      Remove the 2 hole plugs.

    13. A01W0C9

      Remove the 2 bolts.

    14. Disconnect the drain cooler hose.

      A01W14NE02
      Text in Illustration
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
    15. Remove the 6 bolts and nut as shown in the illustration.

    16. Disengage the 3 guides and remove the instrument panel reinforcement with air conditioning unit as shown in the illustration.

      A01W4VI
  40. REMOVE AIR CONDITIONING UNIT ASSEMBLY


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

      A01W3B0
  41. REMOVE BLOWER ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  42. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for LHD)


    1. Disconnect each connector.

      A01VZMAE04
      Text in Illustration
      *A for 3 Zone Type - -
    2. Disengage each clamp and remove the air conditioning harness assembly.

  43. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (for RHD)


    1. Disconnect each connector.

      A01W1MPE01
      Text in Illustration
      *A for 3 Zone Type - -
    2. Disengage each clamp and remove the air conditioning harness assembly.

  44. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A01W3MO

      Disengage the 2 claws and 2 guides to remove the No. 6 heater to register duct assembly as shown in the illustration.

  45. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01W1G5

      Disengage the 2 claws and guide to remove the No. 1 air duct sub-assembly as shown in the illustration.

  46. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A01W4IP

      Disengage the 2 claws and guide to remove the No. 4 air duct sub-assembly as shown in the illustration.

  47. REMOVE HEATER PACKING


    1. A01W03G

      Remove the heater packing as shown in the illustration.

  48. REMOVE COOLER THERMISTOR HOSE


    1. A01W1KY

      Disengage the clamp and remove the cooler thermistor hose.

  49. REMOVE ASPIRATOR PIPE


    1. A01W56G

      Disengage the 2 claws and remove the aspirator pipe.

  50. REMOVE DRAIN COOLER HOSE


    1. A01VZQF

      Remove the drain cooler hose.