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AIR CONDITIONING UNIT (for Hatchback): Removal

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing DIAGNOSIS SYSTEM .

HINT:

Use the same procedure for both the RH and LH sides.

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 

    Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

  2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See ON-VEHICLE INSPECTION  )
  3. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  4. REMOVE FRONT WIPER ARM HEAD CAP  (See REMOVAL )
  5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  7. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE COWL TOP VENTILATOR LOUVER LH  (See REMOVAL )
  10. REMOVE FRONT WIPER MOTOR AND LINK  (See REMOVAL )
  11. REMOVE NO. 2 COWL TO REGISTER DUCT SUB-ASSEMBLY  REMOVAL 
  12. REMOVE COWL TOP PANEL OUTER  REMOVAL 
  13. DISCONNECT SUCTION TUBE SUB-ASSEMBLY 
    1. Remove the bolt.
    2. Turn the hook type connector clockwise and disconnect the suction tube.
    3. Remove the O-ring from the suction tube.
      NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  14. DISCONNECT LIQUID TUBE SUB-ASSEMBLY 
    1. Disconnect the liquid tube.
      Fig 1: Turning Hook Type Connector Clockwise
      G04829593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from liquid tube.
      NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
  15. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water outlet hose from the heater unit.
      Fig 2: Locating Heater Water Outlet Hose
      G04829594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT HEATER WATER INLET HOSE A 
    1. Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water inlet hose from the heater unit.
  17. BOLTS, SCREWS AND NUTS TABLE  (See REMOVAL )
  18. REMOVE INSTRUMENT PANEL FINISH PANEL END LH  (See REMOVAL )
  19. REMOVE INSTRUMENT PANEL FINISH PANEL END RH  (See REMOVAL )
  20. REMOVE INSTRUMENT CLUSTER FINISH PANEL  (See REMOVAL )
    Fig 3: Locating Heater Water Inlet Hose
    G04829595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE COMBINATION METER ASSEMBLY  (See REMOVAL )
  22. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER (See REMOVAL  )
  23. REMOVE RADIO TUNER OPENING COVER (w/o Radio Receiver) 
    1. Remove the 4 bolts and the radio tuner opening cover.
  24. REMOVE RADIO RECEIVER ASSEMBLY  (See REMOVAL )
  25. REMOVE AIR CONDITIONER PANEL SUB-ASSEMBLY (See REMOVAL  )
  26. DISCONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (See REMOVAL  )
    Fig 4: Identifying Radio Tuner Opening Cover Bolts
    G04829681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (See REMOVAL  )
  28. DISCONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (See REMOVAL  )
  29. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See REMOVAL )
  30. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See REMOVAL )
  31. REMOVE FRONT PILLAR GARNISH RH  (See REMOVAL )
  32. REMOVE FRONT PILLAR GARNISH LH  (See REMOVAL )
  33. REMOVE NO. 1 SWITCH HOLE BASE  (See REMOVAL )
  34. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  (See REMOVAL )
  35. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  36. REMOVE FRONT DOOR SCUFF PLATE RH  (See REMOVAL )
  37. REMOVE FRONT DOOR SCUFF PLATE LH  (See REMOVAL )
  38. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY RH  (See REMOVAL )
  39. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH  (See REMOVAL )
  40. REMOVE COWL SIDE TRIM BOARD RH  (See REMOVAL )
  41. REMOVE COWL SIDE TRIM BOARD LH  (See REMOVAL )
  42. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  43. REMOVE SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  44. REMOVE CONSOLE BOX REAR COVER  (See REMOVAL )
  45. REMOVE CONSOLE BOX CARPET  (See REMOVAL )
  46. REMOVE CONSOLE BOX ASSEMBLY REAR  (See REMOVAL )
  47. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER  (See REMOVAL )
  48. REMOVE INSTRUMENT PANEL BOX  (See REMOVAL )
  49. REMOVE NO. 6 HEATER TO REGISTER DUCT ASSEMBLY  (See REMOVAL )
  50. DISCONNECT ANTENNA CORD SUB-ASSEMBLY  (See REMOVAL )
  51. SEPARATE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY  (See REMOVAL )
  52. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  53. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
  54. REMOVE STEERING PAD  (See REMOVAL )
  55. REMOVE STEERING WHEEL ASSEMBLY  (See REMOVAL )
  56. REMOVE STEERING COLUMN COVER  (See REMOVAL )
  57. REMOVE COMBINATION SWITCH ASSEMBLY  REMOVAL 
  58. DISCONNECT POWER STEERING ECU  REMOVAL 
  59. REMOVE INSTRUMENT PANEL SUB REINFORCEMENT  REMOVAL 
  60. REMOVE COLUMN HOLE COVER SILENCER SHEET  REMOVAL 
  61. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY 
    1. Place matchmarks on the sliding yoke of the steering intermediate shaft and the power steering link.
    2. Loosen bolt A, remove bolt B and separate the steering yoke.
      Fig 5: Identifying Steering Yoke Bolt Matchmarks
      G04829596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE BRAKE PEDAL (for Automatic Transaxle)  REMOVAL 
  63. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (for Manual Transaxle)  (See REMOVAL )
  64. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  65. REMOVE STEERING COLUMN ASSEMBLY  REMOVAL 
  66. REMOVE DEFROSTER NOZZLE ASSEMBLY 
    1. Disconnect the connectors and clamps.
    2. Disengage the 5 claws and remove the defroster nozzle.
      Fig 6: Locating Claws For Defroster Nozzle
      G04829683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE REAR NO. 2 AIR DUCT (for Cold Area Specification Vehicles) 
    1. Disengage the 4 claws and remove the air duct.
      Fig 7: Identifying Claws For Air Duct
      G04829599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE REAR NO. 1 AIR DUCT (for Cold Area Specification Vehicles) 
    1. Disengage the 2 claws and remove the air duct.
      Fig 8: Locating Claws For No. 1 Air Duct
      G04829600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE REAR NO. 3 AIR DUCT (for Cold Area Specification Vehicles) 
    1. Disengage the 4 claws and remove the air duct.
      Fig 9: Locating Claws For No. 3 Air Duct
      G04829601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Disengage the clamp.
    2. Remove 2 bolts, screw and nut and remove the instrument panel brace.
      Fig 10: Locating Instrument Panel Brace Bolts
      G04829687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. SEPARATE MAIN BODY ECU 
    1. Disconnect the 5 connectors and 3 clamps.
      Fig 11: Locating Connectors And Clamps
      G04829688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and separate the main body ECU.
      Fig 12: Locating Main Body ECU Bolts
      G04829604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. SEPARATE CONNECTOR NO. 2 HOLDER 
    1. Remove the bolt.
      Fig 13: Identifying Connector No. 2 Holder
      G04829690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connectors and separate the connector No. 2 holder.
      Fig 14: Identifying Connector No. 2 Holder
      G04829691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Disconnect the drain hose.
      Fig 15: Locating Drain Hose
      G04829607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the ground wire.
      Fig 16: Identifying Bolt For Ground Wire
      G04829693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Disengage the clamps.
      Fig 17: Locating Connector
      G04829694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 18: Identifying Clamps
      G04829695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the connectors and clamps.
      Fig 19: Locating Connectors And Clamps
      G04829611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 bolts and the nut.
      Fig 20: Identifying Bolts And Nut
      G04829697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 9 bolts and remove the instrument panel reinforcement together with the air conditioning unit.
      Fig 21: Identifying Instrument Panel Reinforcement Bolts
      G04829698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the connector and the 3 clamps.
      Fig 22: Locating Connector Clamps
      G04829699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 3 screws and the air conditioning unit.
      Fig 23: Locating Air Conditioning Unit Screws
      G04829700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Remove the screw and the air conditioning amplifier.
      Fig 24: Locating Screw For Air Conditioning Amplifier
      G04829615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE AIR CONDITIONING UNIT 
    1. Remove the 3 screws and the air conditioning unit.
      Fig 25: Identifying Screws For Air Conditioning Unit
      G04829702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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