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Air Conditioning Unit: Removal

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

      Fig 1: Installing SST To Piping Clamp
      G05195318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down SST and release the clamp lock.
      NOTE: Be careful not to deform the tube, when pushing SST.
    3. Pull SST slightly and push the release lever, then remove the piping clamp with SST.
    4. Remove the piping clamp from SST.
      Fig 2: Removing Piping Clamp From SST
      G04966028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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.
    Fig 3: Disconnecting Cooler Refrigerant Suction Hose
    G05195320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 
    1. Using pliers, grip the claws of clip and slide the clip and disconnect the heater inlet water hose.
      Fig 4: Identifying Heater Inlet Water Hose
      G05195321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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  (See REMOVAL )
  7. REMOVE INSTRUMENT PANEL LWR PAD INSERT LH 
    1. Remove the 3 screws and instrument panel LWR pad insert LH.
    Fig 5: Identifying Instrument Panel LWR Pad Insert LH Screws
    G05195322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO. 1 
    1. 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.

      Fig 6: Removing Clips And Take Up Floor Carpet
      G05195323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp and floor shift parking lock cable assembly.
      Fig 7: Identifying Clamp And Floor Shift Parking Lock Cable Assembly
      G05195324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
    4. Remove the bolt, nut and instrument panel brace sub-assembly No. 1.
    Fig 8: Identifying Bolt, Nut And Instrument Panel Brace Sub-Assembly No. 1
    G05195325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE AIR DUCT NO. 1 
    1. Release the 2 fitting claws, remove the air duct No. 1.
    Fig 9: Identifying Air Duct No. 1 Fitting Claws
    G05195326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE AIR DUCT NO. 2 
    1. Remove the screw.
    2. Release the 2 fitting claws, remove the air duct No. 2.
    Fig 10: Identifying Air Duct No. 2 Fitting Claws
    G05195327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE AIR DUCT REAR NO. 3 (for Cold Area) 
    1. Release the 6 fitting claws, remove the air duct rear No. 3.
    Fig 11: Identifying Air Duct Rear No. 3 Fitting Claws
    G05195328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE AIR DUCT REAR NO. 4 (for Cold Area) 
    1. 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.

      Fig 12: Identifying Floor Carpet Clips
      G05195329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 6 fitting claws, remove the air duct rear No. 4.
    Fig 13: Identifying Air Duct Rear No. 4 Fitting Claws
    G05195330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE HEATER TO REGISTER DUCT NO. 2 
    1. Remove the 2 clips and heater to register duct No. 2.
    Fig 14: Identifying Register Duct No. 2 Clips
    G05195331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE HEATER TO REGISTER DUCT NO. 1 
    1. Remove the 2 clips and heater to register duct No. 1.
    Fig 15: Identifying Register Duct No. 1 Clips
    G05195332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE DEFROSTER NOZZLE ASSEMBLY 
    1. Release the 3 fitting claws, remove the defroster nozzle assembly.
    Fig 16: Identifying Defroster Nozzle Assembly Fitting Claws
    G05195333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY 
    1. Disconnect the outer cable from the clamp.
    2. 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.
    Fig 17: Disconnecting Inner Cable And Defroster Damper Control Cable Sub-Assembly
    G05195334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY 
    1. Disconnect the outer cable from the clamp.
    2. 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.
    Fig 18: Disconnecting Inner Cable And Air mix Damper Control Cable Sub-Assembly
    G05195335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT ECM 
    1. 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.
    Fig 19: Identifying ECM And Bolts
    G05195336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER 
    1. Remove the 2 nuts and instrument panel to cowl brace center.
    Fig 20: Identifying Nuts And Instrument Panel
    G05195337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT STEERING COLUMN ASSEMBLY 
    1. Disconnect the connector, remove the 2 clamps.
      Fig 21: Disconnecting Connector And Clamps
      G05195338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, disconnect the steering column assembly.
      Fig 22: Disconnecting Steering Column Assembly Bolts
      G05195339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Remove the 8 screws and 2 earth wires from the instrument panel reinforcement.
      Fig 23: Identifying Screws And Earth Wires
      G05195340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 6 clamps and wire harness.
      Fig 24: Identifying Clamps And Wire Harness
      G05195341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and instrument panel reinforcement.
    Fig 25: Identifying Bolts And Instrument Panel Reinforcement
    G05195342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE AIR CONDITIONING UNIT ASSEMBLY 
    1. Release the 2 fitting claws, disconnect the connector holder.

      HINT:

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

      Fig 26: Locating Connector Holder Lock Points
      G05195343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the blower with fan motor sub-assembly.
      Fig 27: Disconnecting Connector To Blower W/Fan Motor Sub-Assembly
      G05195344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector from the damper servo sub-assembly.
      Fig 28: Disconnecting Connector From Damper Servo Sub-Assembly
      G05195345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector from the cooler thermistor No. 1.
      Fig 29: Disconnecting Connector From Cooler Thermistor No. 1
      G05195346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 nuts, bolt and air conditioner unit assembly.
      Fig 30: Identifying Nuts, Bolt And Air Conditioner Unit Assembly
      G05195347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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