FRONT AIR CONDITIONING UNIT REMOVAL

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

CAUTION:

w/ Airbag System:

B0027VM

Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing.

for Type A: Click here

for Type B: Click here

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DRAIN ENGINE COOLANT (w/ Heater)


    1. for 1GR-FE:

      Click here

    2. for 1GD-FTV:

      Click here

    3. for 2GD-FTV:

      Click here

    4. for 1KD-FTV:

      Click here

    5. for 2KD-FTV:

      Click here

    6. for 1TR-FE:

      Click here

    7. for 2TR-FE:

      Click here

  3. REMOVE NO. 2 WIRING HARNESS PROTECTOR (for GD Series Engine, LHD)


    1. B0028H2

      Remove the 2 nuts.

    2. Detach the claw and remove the No. 2 wiring harness protector.

  4. REMOVE VACUUM HOSE ASSEMBLY (for GD Series Engine, LHD)


    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the vacuum hose.

      Note

      Do not apply excessive force to the vacuum hose.

    2. Detach the claw.

    3. Remove the 2 bolts and remove the vacuum hose assembly.

      B0024XH

  5. REMOVE NO. 2 WIRING HARNESS PROTECTOR (for GD Series Engine, RHD)


    1. B0026M1

      Remove the 2 nuts.

    2. Detach the claw, guide and remove the No. 2 wiring harness protector.

  6. REMOVE VACUUM HOSE ASSEMBLY (for GD Series Engine, RHD)


    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the vacuum hose.

      Note

      Do not apply excessive force to the vacuum hose.

    2. Detach the claw.

    3. Remove the 2 bolts and remove the vacuum hose assembly.

      B0028UZ

  7. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (for 1GD-FTV, 2GD-FTV)


    1. B0026BI

      Remove the bolt and disconnect the air conditioner tube and accessory assembly.

    2. 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 the entry of moisture and foreign matter.

  8. DISCONNECT SUCTION PIPE SUB-ASSEMBLY (except 1GD-FTV, 2GD-FTV)


    1. B0026T3C01
      B0069FO Remove in this Direction

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

    2. B00262B

      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 the entry of moisture and foreign matter.

  9. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (except 1GD-FTV, 2GD-FTV)


    1. B0025XS

      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 the entry of moisture and foreign matter.

  10. REMOVE INTAKE AIR SURGE TANK (for 1GR-FE)

    Click here

  11. DISCONNECT HEATER WATER OUTLET HOSE (w/ Heater)


    1. B00254E

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

      Note


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

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

  12. DISCONNECT HEATER WATER INLET HOSE (w/ Heater)


    1. B0024JA

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

      Note


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

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

  13. REMOVE HEATER GROMMET (w/ Heater)

    B00261L

    1. Detach the claw and remove the heater grommet.

  14. REMOVE FRONT SEAT ASSEMBLY LH


    1. for Manual Seat:

      Click here

    2. for Power Seat:

      Click here

    3. for Bench Seat Type:

      Click here

  15. REMOVE FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  16. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  17. REMOVE CONSOLE BOX ASSEMBLY (w/ Console Box Lid)

    Click here

  18. REMOVE FRONT CONSOLE BOX (w/o Console Box Lid)

    Click here

  19. REMOVE NO. 1 AIR DUCT


    1. B0026JT

      Remove the bolt.

    2. Detach the claw and remove the No. 1 air duct.

      Note


      • When removing, do not crack or deform the lower heater case of the air conditioning radiator assembly.

      • If the No. 1 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace it with a new one.

  20. REMOVE NO. 2 AIR DUCT


    1. B0027KE

      Detach the claw and remove the No. 2 air duct.

      Note


      • When removing, do not crack or deform the lower heater case of the air conditioning radiator assembly.

      • If the No. 2 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace it with a new one.

  21. REMOVE STEERING COLUMN ASSEMBLY

    Click here

  22. REMOVE FRONT DOOR SCUFF PLATE LH


    1. for Double Cab:

      Click here

    2. for Single Cab:

      Click here

    3. for Smart Cab:

      Click here

  23. REMOVE COWL SIDE TRIM BOARD LH

    Click here

  24. REMOVE FRONT DOOR SCUFF PLATE RH


    1. for Double Cab:

      Click here

    2. for Single Cab:

      Click here

    3. for Smart Cab:

      Click here

  25. REMOVE COWL SIDE TRIM BOARD RH

    Click here

  26. REMOVE REAR DOOR SCUFF PLATE LH (for Double Cab)

    Click here

  27. REMOVE REAR DOOR SCUFF PLATE RH (for Double Cab)

    Click here

  28. REMOVE LOWER CENTER PILLAR GARNISH LH (for Double Cab)

    Click here

  29. REMOVE LOWER CENTER PILLAR GARNISH RH (for Double Cab)

    Click here

  30. REMOVE FRONT FLOOR CARPET ASSEMBLY


    1. for LHD:

      Remove the 5 clips.

      B0025LRC02
      *A for LHD - -
      B00692L Fastener B0069FO Remove in this Direction

    2. for RHD:

      Remove the 4 clips.

    3. Detach each fastener.

    4. Detach the guide and fold back the front floor carpet assembly as shown in the illustration.

  31. REMOVE NO. 1 INSTRUMENT PANEL INNER BRACKET COVER LH (for LHD)

    B00270E

    1. Remove the 3 clips and No. 1 instrument panel inner bracket cover LH

  32. REMOVE NO. 3 DASH PANEL INSULATOR PAD


    1. B0024Q3C01
      B0069FO Remove in this Direction

      Remove the No. 3 dash panel insulator pad as shown in the illustration.

  33. REMOVE NO. 2 DASH PANEL INSULATOR PAD


    1. B0024F7C01
      B0069FO Remove in this Direction

      Remove the No. 2 dash panel insulator pad as shown in the illustration.

  34. REMOVE NO. 1 CONSOLE BOX DUCT (w/ Rear Resistor Duct)


    1. B0025UZC02
      *A w/ Smart Entry and Start System

      for Automatic Transmission:


      1. Remove the 2 bolts.

      2. w/ Smart Entry and Start System:

        Detach the clamp and remove the No. 2 console box mounting bracket.

      3. B00283J

        Remove the 2 clips and No. 1 console box duct.

    2. B0028XPC01
      *A w/ Smart Entry and Start System

      for Manual Transmission:


      1. Remove the 2 bolts.

      2. w/ Smart Entry and Start System:

        Detach the clamp and remove the No. 2 console box mounting bracket.

      3. B0028WB

        Remove the 3 clips and No. 1 console box duct.

  35. REMOVE NO. 4 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B0026W1

      Detach the claw and remove the No. 4 rear air duct.

  36. REMOVE NO. 5 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B0024VN

      Detach the claw and remove the No. 5 rear air duct.

  37. REMOVE NO. 2 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B0028GM

      Detach the claw and remove the No. 2 rear air duct.

  38. REMOVE NO. 3 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B00280G

      Detach the claw and remove the No. 3 rear air duct.

  39. REMOVE NO. 1 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B0028EQ

      Remove the 2 clips and remove the No. 1 rear air duct.

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


    1. B00260ZC03
      B0068HS Nut
      B006964 Bolt
      B0069AV Screw

      Detach the clamp.

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

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


    1. B0028P4C03
      B0068HS Nut
      B006964 Bolt
      B0069AV Screw

      Remove the nut, bolt, 3 screws and No. 2 instrument panel brace sub-assembly.

  42. DISCONNECT INSTRUMENT PANEL WIRE


    1. B002756

      for Automatic Air Conditioning System:


      1. Disconnect the connector.

      2. Detach the clamp.

    2. B0026K0

      for Manual Air Conditioning System, Manual Cooler System:


      1. Disconnect the connector.

      2. Detach the clamp.

    3. Remove each bolt and each ground wire.

      B0028QFC01
      *A for Manual Air Conditioning System, Manual Cooler System *B for Automatic Air Conditioning System
      *C w/ PTC Heater - -
      *1 Ground Wire - -

    4. Disconnect each connector and detach each clamp.

    5. Remove each bolt, nut and screw, and then disconnect the instrument panel wire.

  43. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

    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 assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. B0025PLC01
      *A for Driver Side
      B00692L Protective Tape

      Put protective tape around the hole plug.

    2. Using a screwdriver with its tip wrapped with protective tape, remove the 2 hole plugs.

    3. for Automatic Transmission:

      Remove the 11 bolts.

      B002912C02
      *A for Manual Transmission - -
      B0068HS Bolt A B006964 Bolt B
      B0069AV Bolt C B0068S6 Bolt D

    4. for Manual Transmission:

      Remove the 12 bolts.

  44. REMOVE DEFROSTER NOZZLE ASSEMBLY

    B00279A

    1. Detach the claw and remove the defroster nozzle assembly.

  45. REMOVE AIR CONDITIONING UNIT ASSEMBLY

    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 assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. Disconnect the drain cooler hose.

      B00296M

    2. Remove the nut and air conditioning unit assembly and instrument panel reinforcement assembly.

  46. REMOVE NO. 3 AIR DUCT


    1. B0027NY

      Detach the claw and remove the No. 3 air duct.