REMOVAL AND INSTALLATION


Pre-removal operation
  • Engine Coolant Draining (Refer to GROUP 14 on-vehicle service ).
  • Discharging refrigerant (Refer to )
  • Floor console assembly removal (Refer to GROUP 52A - Floor console ).
  • Rear heater duct removal (Refer to ).
  • Instrument panel assembly removal (Refer to GROUP 52A - Instrumental Panel ).
  • HBB buzzer removal (Refer to GROUP 35A - HBB buzzer ).
  • ABS-ECU removal (Refer to GROUP 35B - ABS-ECU ).
  • Transfer-ECU removal (Refer to GROUP 22A - 4WD-indicator-ECU ).
  • SRS-ECU removal (Refer to GROUP 52B - SRS-ECU ).
  • Cowl side trim removal (Refer to GROUP 52A - Trim ).
  • Battery removal (Refer to GROUP 54A - Battery ).
  • Engine cover removal.
  • Fuel filter mounting bolt <4M40 or 4M41> (Refer to GROUP 13E- <4M40> - <4M41>).
  • Under cover removal (Refer to GROUP 51 - Under cover ).
  • EGR removal (Refer to GROUP 17 - ).

 Post-installation Operation
  • EGR installation (Refer to GROUP 17 - ).
  • Under cover installation (Refer to GROUP 51 - Under cover ).
  • Fuel filter mounting bolt <4M40 or 4M41> (Refer to GROUP 13E- <4M40> - <4M41>).
  • Engine cover installation.
  • Battery installation (Refer to GROUP 54A - Battery ).
  • Cowl side trim installation (Refer to GROUP 52A - Trim ).
  • SRS-ECU installation (Refer to GROUP 52B - SRS-ECU ).
  • Transfer-ECU installation (Refer to GROUP 22A - 4WD-indicator-ECU ).
  • ABS-ECU installation (Refer to GROUP 35B - ABS-ECU ).
  • HBB buzzer installation (Refer to GROUP 35A - HBB buzzer ).
  • Instrument panel assembly installation (Refer to GROUP 52A - Instrumental Panel ).
  • Rear heater duct installation (Refer to Duct, ).
  • Floor console assembly installation (Refer to GROUP 52A - Floor console assembly ).
  • Charging refrigerant (Refer to ).
  • Engine Coolant Refilling (Refer to GROUP 14 on-vehicle service ).




Removal steps
<<A>>
1.
 Suction flexible hose connection
<<A>>
2.
 Liquid pipe B connection


3.
 O-ring


4.
 Heater hose clamp


5.
 Heater hose connection


6.
 Foot duct A


7.
 Foot duct B


8.
 Foot duct D
<<B>>
·
 Wiring harness and clamps


9.
 Front deck crossmember


10.
 Blower unit assembly


11.
 Drain hose


12.
 Heater unit assembly


13.
 Flange bracket

REMOVAL SERVICE POINTS

<<A>> SUCTION FLEXIBLE HOSE AND LIQUID PIPE B DISCONNECTION
caution Use the plug which is not breathable because A/C compressor oil or receiver have high hygroscopicity.
Plug the removed nipple of the pipe, hose and expansion valve to prevent the entry of dust and dirt.

<<B>> CONNECTOR DISCONNECTION






Disconnect the following connectors to remove the front deck crossmember.
Connector number
 Connector name
D-114
 Instrument panel wiring harness and door wiring harness (RH) connection
D-115
 Instrument panel wiring harness and door wiring harness (RH) connection
D-130
 Instrument panel wiring harness and rear display wiring harness connection
D-131
 Instrument panel wiring harness and door wiring harness (LH) connection
D-132
 Instrument panel wiring harness and door wiring harness (LH) connection
D-133
 Instrument panel wiring harness and door wiring harness (LH) connection
D-219
 Instrument panel wiring harness and floor wiring harness (RH) connection
D-220
 Instrument panel wiring harness and floor wiring harness (RH) connection
D-221
 Instrument panel wiring harness and floor wiring harness (RH) connection
D-222
 Instrument panel wiring harness and control wiring harness (RH) connection
D-226
 Instrument panel wiring harness and transmission wiring harness connection
D-227
 Instrument panel wiring harness and transmission wiring harness connection
D-228
 Instrument panel wiring harness and transmission wiring harness connection
D-229
 Instrument panel wiring harness and floor wiring harness connection
D-230
 Instrument panel wiring harness and floor wiring harness connection
D-234
 Instrument panel wiring harness and floor wiring harness (LH) connection
D-235
 Instrument panel wiring harness and floor wiring harness (LH) connection
D-236
 Instrument panel wiring harness and floor wiring harness (LH) connection
D-237
 Instrument panel wiring harness and floor wiring harness (LH) connection
D-238
 Instrument panel wiring harness and front wiring harness connection
D-239
 Instrument panel wiring harness and front wiring harness connection
D-240
 Instrument panel wiring harness and front wiring harness connection
D-241
 Instrument panel wiring harness and front wiring harness connection