AIR CONDITIONING UNIT REMOVAL


  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE NO.1 ENGINE UNDER COVER (w/ Under Cover and Intercooler)

  5. DRAIN ENGINE COOLANT


    1. for 1KD-FTV: Click here

    2. for 2KD-FTV: Click here

    3. for 1TR-FE: Click here

    4. for 2TR-FE: Click here

    5. for 5L-E: Click here

    6. for 1GD-FTV: Click here

  6. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. for 1KD-FTV: Click here

    2. for 2KD-FTV: Click here

    3. for 1GD-FTV: Click here

  7. DISCONNECT COOLER REFRIGERANT SUCTION PIPE A


    1. B007OU4E01
      Text in Illustration
      *1 Cooler Refrigerant Suction Pipe A
      *2 Hook Connector
      *3 Cooler Refrigerant Liquid Pipe B

      Remove the bolt, and slide the hook connector.

    2. Disconnect the cooler refrigerant suction pipe A.

    3. Remove the O-ring from the cooler refrigerant suction pipe A.

      Note

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

  8. DISCONNECT COOLER REFRIGERANT LIQUID PIPE B


    1. Disconnect the cooler refrigerant liquid pipe B.

    2. Remove the O-ring from the cooler refrigerant liquid pipe B.

      Note

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

  9. DISCONNECT HEATER WATER HOSE OUTLET


    1. B007UDYE01
      Text in Illustration
      *1 Heater Outlet Water Hose
      *2 Heater Water Inlet Hose A

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

  10. DISCONNECT HEATER WATER HOSE INLET A

    Tech Tips

    Disconnection of the heater water outlet hose A is the same as for the heater water inlet hose A.

  11. REMOVE INSTRUMENT PANEL ASSEMBLY

    Click here

  12. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  13. REMOVE AIR DUCT NO.1


    1. B007QA6E01

      Remove the clip.

    2. Release the 2 claws and remove the air duct No.1.

  14. DISCONNECT PARKING BRAKE CONTROL HANDLE SUB-ASSEMBLY


    1. B007V18

      Remove the 2 bolts and disconnect the parking brake control handle sub-assembly.

  15. REMOVE INSTRUMENT PANEL TO FLOOR BRACE SUB-ASSEMBLY


    1. B007POP

      Remove the 5 bolts and the instrument panel to floor brace sub-assembly.

  16. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Remove the clamps and connectors, and then disconnect the wire harness.

      B007TC4E04
      Text in Illustration
      *A w/ PTC *B for Wide Body

    2. Remove the bolts, nuts and junction blocks.

    3. Remove the 2 caps and 2 bolts.

      B007TYNE02
      Text in Illustration
      *A for Manual Transmission - -
      *1 ''Torx'' Bolt *2 Collar

    4. Remove the 2 bolts and nut. (AUTOMATIC TRANSMISSION)

    5. Remove the 3bolts and nut. (MANUAL TRANSMISSION)

    6. Using a "Torx" socket wrench (T40), remove the 4 "Torx" bolts.

      Tech Tips

      The "Torx" bolts on the passenger side can be removed with the collar for adjustment.

    7. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly.

  17. REMOVE AIR CONDITIONER UNIT ASSEMBLY


    1. Remove the 3 bolts and air conditioner unit assembly.

      B007W8S

  18. REMOVE AIR DUCT NO.2


    1. B007QVDE01

      Release the 2 claws and remove the air duct No.2.

  19. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY


    1. B007S32

      for LHD, w/ PTC:


      1. Remove the screw and then disconnect the wire harness.

    2. for RHD, w/ PTC:


      1. B007TPFE01

        Detach the clamp.

    3. B007UFC

      Remove the 3 screws and air conditioning radiator assembly.