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Air Conditioning Unit: Removal

  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  (See REPLACEMENT )
  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. DISCONNECT BATTERY NEGATIVE TERMINAL 
    NOTE: Wait for 90 seconds after disconnecting the terminal to prevent the airbag from deploying. (See PRECAUTION )
  4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  6. REMOVE FRONT FENDER TO COWL SIDE SEAL LH  (See REMOVAL )
  7. REMOVE FRONT FENDER TO COWL SIDE SEAL RH  (See REMOVAL )
  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  10. REMOVE COWL TOP OUTER FRONT PANEL SUB-ASSEMBLY  (See REMOVAL )
  11. DISCONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the bolt, and slide the hook connector.
    2. Disconnect the suction pipe sub-assembly.
    3. Remove the O-ring from the suction hose sub-assembly.
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
    Fig 1: Removing O-Ring From Suction Hose Sub-Assembly
    G04979040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY 
    1. Disconnect the air conditioner tube and accessory.
    2. Remove the O-ring from the air conditioner tube and accessory.
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
  13. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.
    NOTE:
    • Do not apply excessive force to the heater outlet water hose.
    • Prepare a drain pan or cloth in case the coolant leaks.
      Fig 2: Disconnecting Heater Outlet Water Hose
      G04979041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT HEATER INLET WATER HOSE 

    HINT:

    Disconnection procedure for the heater inlet water hose is the same as that for the heater outlet water hose.

  15. REMOVE LOWER NO. 3 STEERING WHEEL COVER  (See REMOVAL )
  16. REMOVE LOWER NO. 2 STEERING WHEEL COVER  (See REMOVAL )
  17. REMOVE STEERING PAD  (See REMOVAL )
  18. REMOVE STEERING WHEEL ASSEMBLY  (See REMOVAL )
  19. REMOVE FRONT DOOR SCUFF PLATE LH  (See REMOVAL )
  20. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH  (See REMOVAL )
  21. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made)  (See REMOVAL )
  22. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made)  (See REMOVAL )
  23. REMOVE STEERING COLUMN COVER (for TMC Made)  (See REMOVAL )
  24. REMOVE STEERING COLUMN COVER (for TMMK Made)  (See REMOVAL )
  25. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  (See REMOVAL )
  26. REMOVE NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  27. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System)  (See REMOVAL )
  28. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System)  (See REMOVAL )
  29. REMOVE INSTRUMENT CLUSTER FINISH PANEL  (See REMOVAL )
  30. REMOVE COMBINATION METER ASSEMBLY (for TMC Made)  (See REMOVAL )
  31. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made)  (See REMOVAL )
  32. REMOVE FRONT DOOR SCUFF PLATE RH  (See REMOVAL )
  33. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH  (See REMOVAL )
  34. REMOVE INSTRUMENT PANEL NO. 2 UNDER COVER SUB-ASSEMBLY  (See REMOVAL )
  35. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY (for TMC Made)  (See REMOVAL )
  36. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY (for TMMK Made)  (See REMOVAL )
  37. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  38. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  39. REMOVE NO. 1 INSTRUMENT CLUSTER FINISH PANEL GARNISH  (See REMOVAL )
  40. REMOVE NO. 2 INSTRUMENT CLUSTER FINISH PANEL GARNISH  (See REMOVAL )
  41. REMOVE FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  42. REMOVE UPPER CONSOLE PANEL (for Manual Transaxle)  (See REMOVAL )
  43. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  44. REMOVE UPPER CONSOLE REAR PANEL SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  45. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMC Made)  (See REMOVAL )
  46. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (for TMMK Made)  (See REMOVAL )
  47. REMOVE INSTRUMENT PANEL NO. 2 REGISTER ASSEMBLY  (See REMOVAL )
  48. REMOVE RADIO RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/o Navigation System)  (See REMOVAL )
  49. REMOVE NAVIGATION RECEIVER WITH HEATER CONTROL PANEL ASSEMBLY (w/ Navigation System)  (See REMOVAL )
  50. REMOVE CONSOLE BOX POCKET  (See REMOVAL )
  51. REMOVE CONSOLE BOX CARPET  (See REMOVAL )
  52. REMOVE CONSOLE BOX ASSEMBLY (for TMC Made)  (See REMOVAL )
  53. REMOVE CONSOLE BOX ASSEMBLY (for TMMK Made)  (See REMOVAL )
  54. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMC Made)  (See REMOVAL )
  55. REMOVE NO. 2 CONSOLE BOX INSERT FRONT (for TMMK Made)  (See REMOVAL )
  56. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMC Made)  (See REMOVAL )
  57. REMOVE NO. 1 CONSOLE BOX INSERT FRONT (for TMMK Made)  (See REMOVAL )
  58. REMOVE FRONT PILLAR GARNISH LH  (See REMOVAL )
  59. REMOVE INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY  (See REMOVAL )
  60. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY  (See REMOVAL )
  61. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)  (See REMOVAL )
  62. REMOVE FRONT PILLAR GARNISH RH  (See REMOVAL )
  63. REMOVE INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY  (See REMOVAL )
  64. REMOVE INSTRUMENT PANEL NO. 2 SPEAKER PANEL SUB-ASSEMBLY  (See REMOVAL )
  65. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)  (See REMOVAL )
  66. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH  (See REMOVAL )
  67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMC Made)  (See REMOVAL )
  68. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for TMMK Made)  (See REMOVAL )
  69. REMOVE NO. 3 INSTRUMENT PANEL STAY  (See DISASSEMBLY )
  70. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Air Conditioning System) 
    1. Remove the clip and No. 1 console box duct.
      Fig 3: Removing Clip And No. 1 Console Box Duct
      G04979042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE FLOOR CARPET BRACKET LH 
    1. Release the clamp.
      Fig 4: Releasing Clamp
      G04979043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the floor carpet.
    3. Remove the 3 clips.
    4. Remove the floor carpet bracket LH.
      Fig 5: Removing Floor Carpet Bracket LH
      G04979044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE FLOOR CARPET BRACKET RH 
    1. Release the clamp.
      Fig 6: Releasing Clamp
      G04979045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the floor carpet.
    3. Remove the 3 clips.
    4. Remove the floor carpet bracket RH.
      Fig 7: Removing Floor Carpet Bracket RH
      G04979046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE REAR NO. 2 AIR DUCT 
    1. Release the 2 claws and remove the rear No. 2 air duct.
      Fig 8: Removing Rear No. 2 Air Duct
      G04979047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE REAR NO. 1 AIR DUCT 
    1. Release the 2 claws and remove the rear No. 1 air duct.
      Fig 9: Removing Rear No. 1 Air Duct
      G04979048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE NO. 1 AIR DUCT  (See REMOVAL )
  76. SEPARATE STEERING COLUMN ASSEMBLY (for TMC Made)  (See REMOVAL )
  77. REMOVE STEERING POST ASSEMBLY (for TMMK Made)  (See REMOVAL )
  78. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Disconnect the 2 connectors.
    2. Remove the 2 bolts and air conditioning amplifier assembly.
      Fig 10: Removing Bolts And Air Conditioning Amplifier Assembly
      G04979049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Remove the 28 clamps, disconnect the 11 connectors, and then disconnect the wire harness.
    2. Remove the 7 nuts, 6 bolts, and junction block.
      Fig 11: Removing Nuts, Bolts, And Junction Block
      G04979050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 caps and 2 bolts from the engine compartment side.
      Fig 12: Removing Caps And Bolts From Engine Compartment Side
      G04979051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and nut.
      Fig 13: Removing Torx Bolts
      G04979052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts.

      HINT:

      The "TORX" bolts on the passenger side can be removed with the collars for adjustment.

    6. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly.
    7. Remove the 3 bolts, 2 screws, and instrument panel reinforcement assembly.
      Fig 14: Removing Bolts, Screws, And Instrument Panel Reinforcement Assembly
      G04979053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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