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Removal and Replacement

Air Conditioning Unit:




Air Conditioning Unit:




AIR CONDITIONING UNIT

REMOVAL

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY




a. Install SST to 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 suction hose sub-assembly.

NOTE:
- Do not use tools like 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 suction hose sub-assembly.

4. DISCONNECT HEATER INLET WATER HOSE




a. Using pliers, grip the claws of 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 INSTRUMENT PANEL SUB-ASSEMBLY LOWER
7. REMOVE INSTRUMENT PANEL LWR PAD INSERT LH




a. Remove the 3 screws and instrument panel LWR pad insert LH.

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




a. Remove 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 clamp and floor shift parking lock cable assembly.




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

9. REMOVE AIR DUCT NO. 1




a. Release the 2 fitting claws, remove the air duct No. 1.

10. REMOVE AIR DUCT NO. 2




a. Remove the screw.
b. Release the 2 fitting claws, remove the air duct No. 2.

11. REMOVE AIR DUCT REAR NO. 3 (for Cold Area)




a. Release the 6 fitting claws, remove the air duct rear No. 3.

12. REMOVE AIR DUCT REAR NO. 4 (for Cold Area)




a. Remove 2 clips and take up the floor carpet.

HINT: Take up the floor carpet as small as the air duct rear No. 4 can be removed.




b. Release the 6 fitting claws, remove the air duct rear No. 4.

13. REMOVE HEATER TO REGISTER DUCT NO. 2




a. Remove the 2 clips and heater to register duct No. 2.

14. REMOVE HEATER TO REGISTER DUCT NO. 1




a. Remove the 2 clips and heater to register duct No. 1.

15. REMOVE DEFROSTER NOZZLE ASSEMBLY




a. Release the 3 fitting claws, remove the defroster nozzle assembly.

16. 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 heater control assembly operationally becomes worse.

17. 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 heater control assembly operationally becomes worse.

18. DISCONNECT ECM




a. Remove the 2 bolts and disconnect the ECM.

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

19. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER




a. Remove the 2 nuts and instrument panel to cowl brace center.

20. DISCONNECT STEERING COLUMN ASSEMBLY




a. Disconnect the connector, remove the 2 clamps.




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

21. REMOVE INSTRUMENT PANEL REINFORCEMENT




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




b. Disconnect the 6 clamps and wire harness.




c. Remove the 6 bolts and instrument panel reinforcement.

22. REMOVE AIR CONDITIONING UNIT ASSEMBLY




a. Release the 2 fitting claws, disconnect the connector holder.

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




b. Disconnect the connector from the blower with 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 conditioner unit assembly.

INSTALLATION

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY




a. Install the air conditioner 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 following 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 with fan motor sub-assembly.




e. Install the 2 fitting claws, connect the connector holder.

2. 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.

3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER
4. 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 heater control assembly operationally 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.

5. 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 heater control assembly operationally 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.

6. INSTALL HEATER CONTROL ASSEMBLY
7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER
8. INSTALL HEATER OUTLET WATER HOSE




a. Using pliers, grip the claws of 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.

9. INSTALL HEATER INLET WATER HOSE

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

10. INSTALL AIR CONDITIONING TUBE 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 air conditioning tube assembly and piping clamp.

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

11. INSTALL SUCTION HOSE SUB-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 suction hose sub-assembly and piping clamp.

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

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