AIR CONDITIONING UNIT (for Automatic Air Conditioning System) REMOVAL

Tech Tips

Use the same procedure for RHD and LHD vehicles.
The procedure listed below is for LHD vehicles.

RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
1. Start up the engine.
2. A/C switch is ON.
3. Operate the cooler compressor with an engine speed of approximately 1,000 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. Using SST, Recover the refrigerant from the A/C system using a refrigerant recovery unit.
  
  SST
  
  09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )
DRAIN ENGINE COOLANT
1. for 1GR-FE:
  
  Click here
2. for 1KD-FTV (w/ EGR Cooler):
  
  Click here
3. for 1KD-FTV (w/o EGR Cooler):
  
  Click here
4. for 2KD-FTV (w/ EGR Cooler):
  
  Click here
5. for 2KD-FTV (w/o EGR Cooler):
  
  Click here
6. for 2TR-FE:
  
  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.
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.
DISCONNECT SUCTION HOSE SUB-ASSEMBLY
1. Text in Illustration
  
  *a Disconnect tube by hand
  
  Remove the bolt and disconnect the suction hose sub-assembly.
  Note
  - Do not use a screwdriver or similar tool to disconnect the suction hose sub-assembly.
  - Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
2. Remove the O-ring from the suction hose sub-assembly.
DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Disconnect the air conditioning tube and accessory assembly.
  Note
  - Do not use a screwdriver or similar tool to disconnect the air conditioning tube and accessory assembly.
  - Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
2. Remove the O-ring from the air conditioning tube and accessory assembly.
DISCONNECT HEATER WATER INLET HOSE
1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose.
  
  Tech Tips
  
  Collect the engine coolant in a container.
DISCONNECT HEATER WATER OUTLET HOSE
1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water outlet hose.
  
  Tech Tips
  
  Collect the engine coolant in a container.
REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY

Click here
REMOVE NO. 2 HEATER TO REGISTER DUCT
1. Remove the 3 clips and No. 2 heater to register duct.
REMOVE NO. 1 HEATER TO REGISTER DUCT
1. Remove the clip.
2. Detach the 3 claws and remove the No. 1 heater to register duct.
REMOVE NO. 3 HEATER TO REGISTER DUCT
1. Remove the clip.
2. Detach the 4 claws and remove the No. 3 heater to register duct.
REMOVE DEFROSTER NOZZLE ASSEMBLY (w/ Defroster)
1. Using a screwdriver, detach the 4 clips and remove the defroster nozzle assembly.
REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

Click here
REMOVE STEERING COLUMN ASSEMBLY

Click here
REMOVE NO. 1 AIR DUCT
1. Detach the 2 claws and remove the No. 1 air duct.
REMOVE NO. 2 AIR DUCT
1. Detach the 2 claws and remove the No. 2 air duct.
REMOVE NO. 4 AIR DUCT
1. Detach the 2 claws and remove the No. 4 air duct.

Text in Illustration
*a	Disconnect tube by hand

REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

Text in Illustration
*1	Screw
*2	Nut A
*3	Nut B
*4	Bolt

Detach the 2 clamps and remove the 2 nuts labeled A.

Disconnect the connectors and remove the driver side junction block.
Remove the screw.
Remove the bolt, nut labeled B and No. 1 instrument panel brace sub-assembly.

REMOVE AIR CONDITIONING DUCT SUB-ASSEMBLY
1. Detach the 2 claws and remove the air conditioning duct sub-assembly.
REMOVE ECM
1. for 1GR-FE:
  
  Click here
2. for 1KD-FTV:
  
  Click here
3. for 1KD-FTV, for DPF:
  
  Click here
4. for 2KD-FTV:
  
  Click here
5. for 2KD-FTV, for DPF:
  
  Click here
6. for 2TR-FE:
  
  Click here
REMOVE INSTRUMENT PANEL REINFORCEMENT
1. Disconnect the connector and detach the 3 clamps.
2. w/o PTC Heater:
  
  Disconnect the connectors and detach the 2 clamps and wire harness.
3. w/ PTC Heater:
  
  Disconnect the connectors and detach the 3 clamps and wire harness.
  
  Text in Illustration
  
  *A w/o PTC Heater
  
  *B w/ PTC Heater
4. Remove the 2 bolts and disconnect the ground wires from the instrument panel reinforcement.
5. Remove the grommet from the vehicle body.
6. Detach the 12 clamps.
7. Disconnect the connectors.
8. Remove the 3 bolts.
9. for Automatic Transmission:
  
  Remove the 7 bolts and instrument panel reinforcement.
10. for Manual Transmission:
  
  Remove the 8 bolts and instrument panel reinforcement.
  
  Text in Illustration
  
  *A for Manual Transmission - -
REMOVE NO. 1 COOLER UNIT DRAIN HOSE
1. Remove the No. 1 cooler unit drain hose.
REMOVE AIR CONDITIONING UNIT ASSEMBLY
1. Remove the bolt, nut and air conditioning unit assembly.
REMOVE NO. 3 AIR DUCT
1. Detach the 2 claws and remove the No. 3 air duct.

Text in Illustration
*A	w/o PTC Heater
*B	w/ PTC Heater