Up to 08/2009

HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL

1. PRECAUTION

Service Precautions

(a) w/ Air Suspension:

NOTICE:
Be sure to read Precaution thoroughly before servicing Suspension Control System.

(b) w/ Navigation System for HDD:

NOTICE:
After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal Navigation System (for HDD).

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

3. ALIGN FRONT WHEELS STRAIGHT AHEAD

4. REMOVE FRONT WHEEL RH

5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

(a) Disable the auto tilt away function by changing the customize parameter Programming and Relearning.

NOTICE:
Record the current customize parameter setting (whether the auto tilt away function is enabled or disabled) in order to restore the current setting after finishing this operation.

HINT
Performing the above operation disables the auto tilt away function when the engine switch is turned off.

(b) Turn the engine switch on (IG). Operate the tilt and telescopic switch to fully extend and lower the steering column assembly.

(c) Turn the engine switch off and disconnect the cable from the negative (-) battery terminal.

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

6. REMOVE FRONT SEAT ASSEMBLY

(a) for LH Side:

(1) Refer to the procedure for Remove Front Seat Assembly Removal.

(b) for RH Side:

HINT
Use the same procedure for the RH side and LH side.

7. REMOVE ENGINE ROOM SIDE COVER Removal

8. REMOVE ENGINE ROOM SIDE COVER LH Removal

9. REMOVE COOL AIR INTAKE DUCT SEAL Removal

10. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH Removal

11. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH Removal

12. REMOVE FRONT FENDER TO COWL SIDE SEAL LH Removal

13. REMOVE FRONT FENDER TO COWL SIDE SEAL RH Removal

14. REMOVE FRONT WIPER ARM HEAD CAP Removal

15. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

16. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

17. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

18. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

19. REMOVE FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension) Removal

20. REMOVE FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

HINT
Use the same procedure for the RH side and LH side.

21. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY Removal

22. DISCONNECT SUCTION PIPE SUB-ASSEMBLY

(a) Disengage the 6 clamps and separate the engine wire harness.

(b) Remove the bolt and slide the hook connector.

(c) Disconnect the suction pipe assembly.

(d) Remove the O-ring from the suction pipe sub-assembly.

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

23. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Disconnect the air conditioning tube and accessory assembly.

(b) Remove the O-ring from the air conditioning tube and accessory assembly.

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

24. DISCONNECT OUTLET HEATER WATER HOSE

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

NOTICE:
* Do not apply excessive force to the outlet heater water hose.
* Prepare a drain pan or cloth in case the coolant leaks.
25. DISCONNECT INLET HEATER WATER HOSE

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

NOTICE:
* Do not apply excessive force to the inlet heater water hose.
* Prepare a drain pan or cloth in case the coolant leaks.
26. REMOVE LOWER NO. 3 STEERING WHEEL COVER Removal

27. REMOVE LOWER NO. 2 STEERING WHEEL COVER Removal

28. REMOVE STEERING PAD Removal

29. REMOVE STEERING WHEEL ASSEMBLY Removal

30. REMOVE LOWER STEERING COLUMN COVER Removal

31. REMOVE UPPER STEERING COLUMN COVER Removal

32. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Removal

33. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY Removal

34. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY Removal

35. REMOVE NO. 2 CONSOLE BOX DUCT Removal

36. REMOVE CONSOLE REAR END PANEL SUB-ASSEMBLY Removal

37. REMOVE MULTI-MEDIA INTERFACE ECU ASSEMBLY (w/ USB Audio System) Removal

38. REMOVE REAR CONSOLE BOX ASSEMBLY Removal

39. REMOVE FRONT DOOR SCUFF PLATE LH Removal

40. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH Removal

41. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Removal

42. REMOVE INSTRUMENT PANEL GARNISH LH Removal

43. REMOVE NO. 1 SWITCH HOLE BASE Removal

44. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Removal

45. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY Removal

46. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY Removal

47. REMOVE BRAKE PEDAL RETURN SPRING Removal

48. REMOVE STOP LIGHT SWITCH ASSEMBLY Removal

49. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS Removal

50. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY Removal

51. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

52. REMOVE STEERING POST ASSEMBLY Removal

53. REMOVE NO. 1 INSTRUMENT PANEL HOLE COVER Removal

54. REMOVE NO. 2 INSTRUMENT PANEL HOLE COVER Removal

55. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL Removal

56. REMOVE COMBINATION METER ASSEMBLY Removal

57. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL Removal

58. REMOVE ACCESSORY METER ASSEMBLY (w/o Navigation System) Removal

59. REMOVE MULTI-DISPLAY ASSEMBLY (w/ Navigation System) Removal

60. REMOVE INSTRUMENT PANEL FINISH PANEL Removal

61. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL Removal

62. REMOVE RADIO RECEIVER ASSEMBLY WITH REGISTER Removal

63. REMOVE CONSOLE BOX Removal

64. REMOVE FRONT DOOR SCUFF PLATE RH Removal

65. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH Removal

66. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Removal

67. REMOVE INSTRUMENT PANEL GARNISH RH Removal

68. REMOVE FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY Removal

69. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY Removal

70. REMOVE REMOTE ENGINE STARTER ECU Removal

71. REMOVE GLASS BREAKAGE SENSOR ECU Removal

72. REMOVE INSTRUMENT SIDE PANEL LH Removal

73. REMOVE FRONT PILLAR GARNISH LH Removal

74. REMOVE INSTRUMENT SIDE PANEL RH Removal

75. REMOVE FRONT PILLAR GARNISH RH Removal

76. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY Removal

77. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY Removal

78. REMOVE NO. 1 SPEAKER OPENING COVER ASSEMBLY Removal

79. REMOVE FRONT NO. 4 SPEAKER ASSEMBLY Removal

80. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH Removal

81. REMOVE SHIFT LEVER ASSEMBLY Removal

82. REMOVE NO. 1 CONSOLE BOX DUCT Removal

83. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY Removal

84. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY Removal

85. REMOVE NO. 3 INSTRUMENT PANEL STAY Removal

86. REMOVE DRIVER SIDE JUNCTION BLOCK ASSEMBLY Removal

87. REMOVE POWER STEERING ECU ASSEMBLY Removal

88. REMOVE TURN SIGNAL FLASHER ASSEMBLY Removal

89. REMOVE CLEARANCE WARNING BUZZER Removal

90. REMOVE DISPLAY AND NAVIGATION MODULE DISPLAY WITH BRACKET (w/ Navigation System for HDD) Removal

91. REMOVE ECU INTEGRATION BOX Removal

92. REMOVE REAR NO. 2 AIR DUCT

(a) Disengage the 2 clamps and fastener.

(b) Disengage the claw and turn back the floor carpet as shown in the illustration.

Text in Illustration

(d) Disengage the claw and remove the rear No. 2 air duct.

93. REMOVE REAR NO. 1 AIR DUCT

(a) Disengage the clamp.

(b) Disengage the 2 claws and remove the rear No. 1 air duct.

94. REMOVE FRONT FLOOR CAUTION PLATE COVER (for TMC Made)

(a) Disengage the claw.

(b) Disengage the guide and remove the frame number cover as shown in the illustration.

95. REMOVE REAR NO. 4 AIR DUCT

(a) Disengage the 2 clamps and fastener.

(b) Disengage the claw and turn back the floor carpet as shown in the illustration.

Text in Illustration

(d) Disengage the claw and remove the rear No. 4 air duct.

96. REMOVE REAR NO. 3 AIR DUCT

(a) Disengage the 2 claws and remove the rear No. 3 air duct.

97. REMOVE CENTER HEATER TO REGISTER SUB DUCT

(a) Remove the 3 clips and center heater to register sub duct.

98. REMOVE NO. 5 INSTRUMENT PANEL BRACKET (w/o Navigation System for HDD)

(a) Remove the 2 No. 5 instrument panel brackets.

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

(a) Disengage each clamp.

(b) Remove the screw.

(c) Remove the 2 bolts, 2 nuts and No. 1 instrument panel brace sub-assembly.

Text in Illustration

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

(a) Disengage each clamp.

(b) Remove the screw.

(c) Remove the 2 bolts, 2 nuts and No. 2 instrument panel brace sub-assembly.

Text in Illustration

101. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY

(a) Disengage each clamp.

(b) Disconnect each connector.

(c) Remove the bolt and disconnect the earth wire.

Text in Illustration

(d) Disengage each clamp.

(e) Disconnect the connector.

(f) Disconnect the blower motor connector.

(g) Disconnect the 2 air conditioning ECU connectors.

(h) Remove the bolt and disconnect the earth wire.

(i) Remove the nut and disconnect the connector holder.

Text in Illustration

(j) Remove the 2 bolts and 2 caps from the engine compartment side.

(k) Remove the nut.

(l) Disconnect the cooler drain hose.

Text in Illustration

(m) Remove the 5 instrument panel safety pad caps.

(n) Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts and the instrument panel reinforcement assembly with air conditioning unit assembly.

Text in Illustration

102. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Disengage the 4 claws and remove the No. 1 air duct sub-assembly.

103. REMOVE AIR CONDITIONING UNIT ASSEMBLY

(a) Remove the 3 bolts and air conditioning unit assembly from the instrument panel reinforcement assembly.