AIR CONDITIONING UNIT > REMOVAL

for Preparation Click here


CAUTION:
Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (Click here).



1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

  1. Start up the engine.

  1. Switch the A/C on.

  1. Turn the blower switch to on.

  1. Operate the cooler compressor with an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the remaining compressor oil from each component, in the cooler compressor.

  1. Stop the engine.



  1. Remove the caps from the service valves on the refrigerant line.


    I104816E02

    Text in illustration 
    *a
    		Engine room side
    *b
    		Wheel house side
    Access to Hi Pressure Side 
    Engine Type
    		RHD
    		LHD
    1KR-FE
    		Engine room
    		Engine room
    1NR-FE
    		Engine room
    		Engine room
    1ND-TV
    		Engine room
    		Engine room
    Access to Low Pressure Side 
    Engine Type
    		RHD
    		LHD
    1KR-FE
    		Wheel house
    		Wheel house
    1NR-FE
    		Wheel house
    		Wheel house
    1ND-TV
    		Wheel house
    		Wheel house

  1. Connect the refrigerant recovery unit.

  1. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

    HINT:
    Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.



2. DRAIN ENGINE COOLANT (for 1KR-FE)


A236548E01

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

  1. Loosen the radiator drain cock plug.
    Text in Illustration 
    *1
    		Water Filler Cap Sub-assembly
    *2
    		Radiator Drain Cock Plug

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Remove the water filler cap sub-assembly.



3. DRAIN ENGINE COOLANT (for 1ND-TV)

CAUTION:
To avoid the danger of being burned, do not remove the reserve tank cap sub-assembly while the engine and reserve tank assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

  1. Loosen the radiator drain cock plug.

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.



  1. Remove the reserve tank cap.


    A201605E01


    Text in Illustration 
    *1
    		Radiator Drain Cock Plug
    		*3
    		Air Bleed Valve 1
    *2
    		Reserve Tank Cap Sub-assembly
    		*4
    		Air Bleed Valve 2



4. DRAIN ENGINE COOLANT (for 1NR-FE)


CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.



A220158E01


Text in Illustration 
*1
Water Filler Cap Sub-assembly
*2
Radiator Drain Cock Plug
*3
Air Bleed Valve
-
-

  1. Loosen the radiator drain cock plug.

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Remove the water filler cap sub-assembly.



5. 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.



6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  1. Remove the windshield wiper motor and link assembly (Click here).



7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY

  1. Remove the instrument panel sub-assembly (Click here).



8. REMOVE STEERING COLUMN ASSEMBLY

  1. Remove the steering column assembly (Click here).



9. DISCONNECT SUCTION PIPE SUB-ASSEMBLY


I104821

  1. Remove the bolt.

  1. Turn the hook connector clockwise and disconnect the suction pipe.

  1. Remove the O-ring from the suction pipe.

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



10. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY

  1. Disconnect the air conditioning tube.

  1. Remove the O-ring from the air conditioning tube.

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



11. DISCONNECT HEATER WATER INLET HOSE


I104819

  1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.



12. DISCONNECT HEATER WATER OUTLET HOSE


I104820

  1. Slide the clip and disconnect the heater water inlet hose from the air conditioning unit.



13. REMOVE ECU INTEGRATION BOX RH (for LHD)


I104823

  1. Disconnect the connectors.

  1. Remove the 2 screws and the ECU integration box.



14. REMOVE ECU INTEGRATION BOX LH (for RHD)


I105004

  1. Disconnect the each connectors.

  1. Remove the 2 screws and the ECU integration box.



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


I104824

  1. Disconnect the connector.

  1. Remove the screw and the windshield wiper relay.



16. REMOVE DOUBLE LOCK DOOR CONTROL RELAY ASSEMBLY (w/ Double Locking System)


I105077

  1. Disconnect the connector.

  1. Remove the screw and the double lock door control relay.



17. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


I104825

  1. Disconnect the connectors on the front side.

  1. Remove the 2 nuts and disengage the guide.

  1. Disconnect the connectors on the back side, then remove the instrument panel junction block.



18. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for LHD)



I104826

  1. Disconnect the connectors.

  1. Disengage the clamps.

  1. Remove the ground wire bolts.



  1. Remove the 9 bolts and nut and separate instrument panel reinforcement with air conditioning unit.


    I104827



  1. Disconnect the connectors and clamps behind the air conditioner unit, and remove the instrument panel reinforcement together with the air conditioner unit.


    I104828E01



19. REMOVE AIR CONDITIONING UNIT ASSEMBLY (for LHD)


I104832

  1. Remove the 2 bolts and screw, and then separate the air conditioner unit and instrument panel reinforcement.

    NOTICE:
    Be sure to support the air conditioner unit, because the air conditioner unit bracket might be broken.

  1. For vehicles with the PTC heater assembly, remove the ground wire bolt.



20. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for RHD)



I104829

  1. Disconnect the connectors.

  1. Disengage the clamps.

  1. Remove the ground wire bolts.



  1. Remove the 9 bolts and nut and separate instrument panel reinforcement with air conditioning unit.


    I104830



  1. Disconnect the connectors and clamps behind the air conditioner unit, and remove the instrument panel reinforcement together with the air conditioner unit.


    I104831E01



21. REMOVE AIR CONDITIONING UNIT ASSEMBLY (for RHD)


I104920

  1. Remove the 2 bolts and screw, and then separate the air conditioner unit and instrument panel reinforcement.

    NOTICE:
    Be sure to support the air conditioner unit, because otherwise, the air conditioner unit bracket might break.

  1. For vehicles with the PTC heater assembly, remove the ground wire bolt.



22. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY


I104833

  1. Disengage the 4 claws and remove the air duct.