Removal and Replacement

Air Conditioning Unit:

Air Conditioning Unit

REMOVAL

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
a. Install SST to the piping clamp.

SST 09870-00015

HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label.

b. Push down SST and release the clamp lock.

NOTE: Be careful not to deform the tube when pushing SST.

c. Pull SST slightly and push the release lever, then remove the piping clamp with SST.
d. Remove the piping clamp from SST.

e. Disconnect the cooler refrigerant suction hose No. 1.

NOTE:
- Do not use tools like a screwdriver to remove the tube.
- Cap the open fittings immediately to keep moisture or dirt out of the system.

3. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY

SST 09870-00015

HINT: Disconnect in the same way as the cooler refrigerant suction hose No. 1.

4. DISCONNECT HEATER INLET WATER HOSE
a. sing pliers, grip the claws of the clip and slide the clip and disconnect the heater inlet water hose.

5. DISCONNECT HEATER OUTLET WATER HOSE

HINT: Disconnect in the same way as the heater inlet water hose.

6. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

7. REMOVE INSTRUMENT PANEL LOWER PAD INSERT LH
a. Remove the 3 screws and instrument panel lower pad insert LH.

8. REMOVE INSTRUMENT PANEL LOWER MOUNT BRACKET NO. 1

9. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO. 1
a. Remove the 2 clips and take up the floor carpet.

HINT: Take up the floor carpet as small as the instrument panel brace sub-assembly No. 1 can be removed.

b. Remove the 3 clamps and floor shift parking lock cable assembly.

c. Remove the screw.
d. Remove the bolt, nut and instrument panel brace sub-assembly No. 1.

10. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO. 2
a. Remove the 2 clips and take up the floor carpet.

HINT: Take up the floor carpet as small as the instrument panel brace sub-assembly No. 2 can be removed.

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

11. REMOVE AIR DUCT NO. 1
a. Release the 2 fitting claws and remove the air duct No. 1.

12. REMOVE AIR DUCT NO. 2
a. Remove the screw.
b. Release the 2 fitting claws and remove the air duct No. 2.

13. REMOVE AIR DUCT REAR NO. 3 (for Cold Area Specification Vehicles)
a. Release the 6 fitting claws and remove the air duct rear No. 3.

14. REMOVE AIR DUCT REAR NO. 4 (for Cold Area Specification Vehicles)
a. Release the 6 fitting claws and remove the air duct rear No. 4.

15. REMOVE HEATER TO REGISTER DUCT NO. 1
a. Remove the 2 clips and heater to register duct No. 1.

16. REMOVE DEFROSTER NOZZLE ASSEMBLY
a. Release the 3 fitting claws and remove the defroster nozzle assembly.

17. DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY
a. Disconnect the outer cable from the clamp.
b. Disconnect the inner cable and defroster damper control cable sub-assembly.

NOTE:
- Be careful not to bend the cable wire.
- If the cable wire bends, the air conditioning control assembly operationality becomes worse.

18. DISCONNECT AIR-MIX DAMPER CONTROL CABLE SUB-ASSEMBLY
a. Disconnect the outer cable from the clamp.
b. Disconnect the inner cable and air-mix damper control cable sub-assembly.

NOTE:
- Be careful not to bend the cable wire.
- If the cable wire bends, the air conditioning control assembly operationality becomes worse.

19. REMOVE ECM
a. Remove the 2 bolts and ECM.

NOTE:
- Do not apply excessive force to the connector of the ECM.
- Do not give any impact to the ECM.

20. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER
a. Remove the 2 nuts and instrument panel to cowl brace center.

21. DISCONNECT STEERING COLUMN ASSEMBLY
a. Disconnect the connector and remove the 2 clamps.

b. Remove the 3 bolts and disconnect the steering column assembly.

22. REMOVE INSTRUMENT PANEL REINFORCEMENT

a. Remove the 8 screws and 2 earth wires from the instrument panel reinforcement.

b. Disconnect the 5 clamps and wire harness.

c. Remove the 6 bolts and instrument panel reinforcement.

23. REMOVE AIR CONDITIONING UNIT ASSEMBLY
a. Release the 2 fitting claws and disconnect the connector holder.

HINT: Release the claw while pressing the lock part in the direction of the arrow.

b. Disconnect the connector from the blower w/fan motor sub-assembly.

c. Disconnect the connector from the damper servo sub-assembly.

d. Disconnect the connector from the cooler thermistor No. 1.

e. Remove the 4 nuts, bolt and air conditioning unit assembly.

INSTALLATION

1. INSTALL CLEAN AIR FILTER
a. Install the air filter to the air conditioning unit assembly.

2. INSTALL AIR CONDITIONING UNIT ASSEMBLY
a. Install the air conditioning unit assembly with the 4 nuts and bolt.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

NOTE: Tighten the nuts and bolt in the order shown in the illustration to install the air conditioner unit assembly.

b. Connect the connector to the cooler thermistor No. 1.

c. Connect the connector to the damper servo sub-assembly.

d. Connect the connector to the blower w/fan motor sub-assembly.

e. Engage the 2 claws, and connect the connector holder.

3. INSTALL ECM
a. Install the ECM with the 2 bolts.

Torque: 3.0 N.m (30 kgf.cm, 26 in.lbf)

NOTE:
- Do not apply excessive force to the connector of the ECM.
- Do not give any impact to the ECM.

4. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY
5. INSTALL AIR CONDITIONING CONTROL ASSEMBLY

6. INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY
a. Set the arm in FACE position.
b. Install the inner cable end to the control lever with the arm in FACE position.
c. Install the outer cable to the cable clamp while slightly pressing it in the direction of the arrow.

NOTE:
- Be careful not to bend the cable wire.
- If the cable wire bends, the air conditioning control assembly operationality becomes worse.

HINT: Operating the mode control lever, check that it properly stops at both ends of FACE and DEF and no recoil is identified.

7. INSTALL AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY
a. Set the arm in MAX. COOL position.
b. Install the inner cable end to the control lever with the arm in MAX. COOL position.
c. Install the outer cable to the cable clamp while slightly pressing it in the direction of the arrow.

NOTE:
- Be careful not to bend the cable wire.
- If the cable wire bends, the air conditioning control assembly operationality becomes worse.

HINT: Operating the temperature control lever, check that it properly stops at both ends of MAX. COOL and MAX. HOT and no recoil is identified.

8. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY

9. INSTALL HEATER OUTLET WATER HOSE
a. Using pliers, grip the claws of the clip and slide the clip and connect the heater outlet water hose.

NOTE:
- The clip is installing so that the projection of the clip may go into the 90° to a direction position.
- Marking of hose is installed upward by vehicle.

10. INSTALL HEATER INLET WATER HOSE

HINT: Connect in the same way as the heater outlet water hose.

11. INSTALL SUCTION HOSE SUB-ASSEMBLY
a. Lubricate a new O-ring with compressor oil and install them to the hose.
Compressor oil: ND-OIL 8 or equivalent
b. Install the cooler refrigerant suction hose No. 1 and piping clamp.

HINT: After connection, check the fitting for claw of the piping clamp.

12. INSTALL AIR CONDITIONING TUBE ASSEMBLY
a. Lubricate a new O-ring with compressor oil and install them to the pipe.

Compressor oil: ND-OIL 8 or equivalent

b. Install the cooler refrigerant liquid pipe A and piping clamp.

HINT: After connection, check the fitting for claw of the piping clamp.

13. ADD COOLANT
14. INSPECT FOR ENGINE COOLANT LEAK
15. CHARGE REFRIGERANT
16. WARM UP ENGINE
17. INSPECT LEAKAGE OF REFRIGERANT