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AIR CONDITIONING UNIT (for Sedan): 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 PRECAUTION .

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 (for 1NZ-FE) (See REPLACEMENT )
  4. 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.
      Fig 1: Turning Hook Type Connector Clockwise
      G04829593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCONNECT LIQUID TUBE SUB-ASSEMBLY 
    1. Disconnect the liquid tube.
    2. Remove the O-ring from the liquid tube.
      NOTE: Seal the openings of the disconnected parts with vinyl tape to prevent moisture and foreign matter from entering.
  6. DISCONNECT HEATER WATER OUTLET HOSE 
    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
  7. DISCONNECT HEATER WATER INLET HOSE 
    1. Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water inlet hose from the heater unit.
  8. BOLTS, SCREWS AND NUTS TABLE  (See REMOVAL )
  9. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER  (See REMOVAL )
  10. REMOVE INSTRUMENT PANEL FINISH PANEL END LH  (See REMOVAL )
    Fig 3: Locating Heater Water Inlet Hose
    G04829595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE INSTRUMENT PANEL FINISH PANEL END RH  (See REMOVAL )
  12. REMOVE INSTRUMENT CLUSTER FINISH PANEL  (See REMOVAL )
  13. REMOVE COMBINATION METER ASSEMBLY  (See REMOVAL )
  14. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER SUB-ASSEMBLY  (See REMOVAL )
  15. REMOVE STEREO OPENING COVER (w/o Radio Receiver)  (See REMOVAL )
  16. REMOVE RADIO RECEIVER ASSEMBLY  (See REMOVAL )
  17. REMOVE AIR CONDITIONING PANEL ASSEMBLY (See REMOVAL  )
  18. DISCONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (See REMOVAL  )
  19. DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (See REMOVAL  )
  20. DISCONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (See REMOVAL  )
  21. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See REMOVAL )
  22. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See REMOVAL )
  23. REMOVE FRONT PILLAR GARNISH RH  (See REMOVAL )
  24. REMOVE FRONT PILLAR GARNISH LH  (See REMOVAL )
  25. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  (See REMOVAL )
  26. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  27. REMOVE FRONT DOOR SCUFF PLATE RH  (See REMOVAL )
  28. REMOVE FRONT DOOR SCUFF PLATE LH  (See REMOVAL )
  29. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY RH  (See REMOVAL )
  30. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH  (See REMOVAL )
  31. REMOVE COWL SIDE TRIM BOARD RH  (See REMOVAL )
  32. REMOVE COWL SIDE TRIM BOARD LH  (See REMOVAL )
  33. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  34. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY  (See REMOVAL )
  35. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY  (See REMOVAL )
  36. REMOVE CONSOLE BOX CARPET  (See REMOVAL )
  37. REMOVE REAR CONSOLE BOX ASSEMBLY  (See REMOVAL )
  38. REMOVE INSTRUMENT PAD LOWER LH  (See REMOVAL )
  39. REMOVE INSTRUMENT PAD LOWER RH  (See REMOVAL )
  40. REMOVE INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY  (See REMOVAL )
  41. REMOVE INSTRUMENT PANEL BOX  (See REMOVAL )
  42. DISCONNECT ANTENNA CORD SUB-ASSEMBLY  (See REMOVAL )
  43. SEPARATE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY  (See REMOVAL )
  44. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  45. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
  46. REMOVE STEERING PAD  (See REMOVAL )
  47. REMOVE STEERING WHEEL ASSEMBLY  (See REMOVAL )
  48. REMOVE STEERING COLUMN COVER  (See REMOVAL )
  49. REMOVE COMBINATION SWITCH ASSEMBLY  REMOVAL 
  50. DISCONNECT POWER STEERING ECU  REMOVAL 
  51. REMOVE INSTRUMENT PANEL SUB REINFORCEMENT  REMOVAL 
  52. REMOVE COLUMN HOLE COVER SILENCER SHEET  REMOVAL 
  53. 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 remove the steering yoke.
  54. REMOVE BRAKE PEDAL (for Automatic Transaxle)  REMOVAL 
  55. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (for Manual Transaxle)  (See REMOVAL )
    Fig 4: Identifying Steering Yoke Bolt Matchmarks
    G04829596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  57. REMOVE STEERING COLUMN ASSEMBLY  REMOVAL 
  58. REMOVE HEATER TO REGISTER DUCT ASSEMBLY 
    1. Disengage the 3 claws and remove the heater to register duct.
      Fig 5: Identifying Claws For Heater To Register Duct
      G04829597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE DEFROSTER NOZZLE ASSEMBLY 
    1. Disconnect the connector and 3 clamps.
    2. Disengage the 5 claws and remove the defroster nozzle.
      Fig 6: Identifying Connector And Clamps
      G04829598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. 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
  61. 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
  62. 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
  63. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Disengage the clamp.
    2. Remove the bolt, screw and nut and remove the instrument panel brace.
      Fig 10: Locating Instrument Panel Brace Screw And Nut
      G04829602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. SEPARATE MAIN BODY ECU (DRIVER SIDE J/B) 
    1. Disconnect the 5 connectors and the 3 clamps.
      Fig 11: Identifying Main Body ECU Connectors And Clamps
      G04829603Courtesy 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
  65. SEPARATE CONNECTOR NO. 2 HOLDER 
    1. Remove the bolt.
      Fig 13: Locating Connector No. 2 Holder
      G04829605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connectors and separate the connector No. 2 holder.
      Fig 14: Separating Connector Holder
      G04829606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. 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: Locating Ground Wire Bolt
      G04829608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and disconnect the ground wire, (for Cold area specification vehicles)
    4. Disconnect the connectors.
      Fig 17: Locating Ground Wire Bolt
      G04829609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamps. 
      Fig 18: Identifying Clamps
      G04829610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the connectors and clamps.
      Fig 19: Locating Connectors And Clamps
      G04829611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and the nut.
      Fig 20: Identifying Instrument Panel Reinforcement Bolts And Nut
      G04829612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 9 bolts and remove the instrument panel reinforcement together with the air conditioning unit.
      Fig 21: Identifying Instrument Panel Reinforcement Bolts And Nuts
      G04829613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 3 screws and the air conditioning unit.
      Fig 22: Identifying Screws For Air Conditioning Unit
      G04829614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Remove the screw and the air conditioning amplifier.
      Fig 23: Locating Screw For Air Conditioning Amplifier
      G04829615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE AIR CONDITIONING UNIT 
    1. Remove the 3 screws and the air conditioning unit.
      Fig 24: Identifying Screws For Air Conditioning Unit
      G04829616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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