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Air Conditioning Unit: Removal

  1. PRECAUTION 

    (See LOWER INSTRUMENT PANEL )

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system (See AIRBAG SYSTEM ).

    HINT:

    Before disconnecting the cable, set the air conditioning control switch to DEF-MODE. (for Automatic Air Conditioning System)

  4. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  (See REPLACEMENT )
  5. REMOVE FRONT WIPER ARM HEAD CAP  (See ON-VEHICLE INSPECTION )
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See ON-VEHICLE INSPECTION )
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  8. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  9. REMOVE CENTER NO. 1 COWL TOP VENTILATOR LOUVER  (See REMOVAL )
  10. REMOVE COWL TOP VENTILATOR LOUVER LH  (See REMOVAL )
  11. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  12. REMOVE OUTER COWL TOP PANEL (for TMC Made)  (See REMOVAL )
  13. REMOVE OUTER COWL TOP PANEL (except TMC Made)  (See REMOVAL )
  14. 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.
  15. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY 
    1. Disconnect the air conditioning tube assembly.
    2. Remove the O-ring from the air conditioning tube assembly.
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
    Fig 1: Identifying Suction Pipe Sub-Assembly
    G06015328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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 a piece of cloth in case the coolant leaks.
  17. 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.

  18. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH  (See REMOVAL )
  19. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL RH  (See REMOVAL )
    Fig 2: Locating Heater Inlet Water Hose
    G06015329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INSTRUMENT PANEL FINISH PANEL END LH  (See REMOVAL )
  21. REMOVE INSTRUMENT PANEL FINISH PANEL END RH  (See REMOVAL )
  22. REMOVE CENTER INSTRUMENT PANEL REGISTER ASSEMBLY  (See REMOVAL )
  23. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY  (See REMOVAL )
  24. REMOVE COMBINATION METER ASSEMBLY  (See REMOVAL )
  25. REMOVE FRONT PILLAR GARNISH LH (w/o Curtain Shield Airbag)  (See REMOVAL )
  26. REMOVE FRONT PILLAR GARNISH LH (w/ Curtain Shield Airbag)  (See REMOVAL )
  27. REMOVE FRONT PILLAR GARNISH RH (w/o Curtain Shield Airbag)  (See REMOVAL )
  28. REMOVE FRONT PILLAR GARNISH RH (w/ Curtain Shield Airbag)  (See REMOVAL )
  29. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY  (See REMOVAL )
  30. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See REMOVAL )
  31. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  (See REMOVAL )
  32. REMOVE NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY  (See REMOVAL )
  33. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See REMOVAL )
  34. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY  (See REMOVAL )
  35. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  36. REMOVE POWER STEERING ECU ASSEMBLY (for 2ZR-FE)  (See REMOVAL )
  37. REMOVE POWER STEERING ECU ASSEMBLY (for 2AZ-FE)  (See REMOVAL )
  38. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  (See REMOVAL )
  39. REMOVE LOWER NO. 3 STEERING WHEEL COVER  (See REMOVAL )
  40. REMOVE LOWER NO. 2 STEERING WHEEL COVER  (See REMOVAL )
  41. REMOVE STEERING PAD  (See REMOVAL )
  42. REMOVE STEERING WHEEL ASSEMBLY  (See REMOVAL )
  43. REMOVE LOWER STEERING COLUMN COVER  (See REMOVAL )
  44. REMOVE UPPER STEERING COLUMN COVER  (See REMOVAL )
  45. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  (See REMOVAL )
  46. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  47. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See REMOVAL )
  48. REMOVE INSTRUMENT PANEL SUB REINFORCEMENT  (See REMOVAL )
  49. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY  (See REMOVAL )
  50. REMOVE TRANSPONDER KEY AMPLIFIER (w/ Smart Key System)  (See REMOVAL )
  51. REMOVE STOP LIGHT SWITCH ASSEMBLY  (See STOP LIGHT SWITCH )
  52. REMOVE STEERING POST ASSEMBLY (for 2ZR-FE)  (See REMOVAL )
  53. REMOVE STEERING POST ASSEMBLY (for 2AZ-FE)  (See REMOVAL )
  54. REMOVE RADIO RECEIVER WITH BRACKET (w/o Navigation System)  (See REMOVAL )
  55. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (w/ Navigation System)  (See REMOVAL )
  56. REMOVE NAVIGATION RECEIVER WITH BRACKET (w/ Navigation System)  (See REMOVAL )
  57. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  58. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  59. REMOVE CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  60. REMOVE CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  61. REMOVE INSTRUMENT PANEL BOX ASSEMBLY  (See REMOVAL )
  62. REMOVE INSTRUMENT PANEL HOLE COVER  (See REMOVAL )
  63. REMOVE AIR CONDITIONING PANEL ASSEMBLY (for Manual Air Conditioning System)  (See REMOVAL )
  64. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System)  (See INSTALLATION )
  65. REMOVE FRONT DOOR SCUFF PLATE LH  (See REMOVAL )
  66. REMOVE COWL SIDE TRIM BOARD LH  (See REMOVAL )
  67. REMOVE FRONT NO. 1 CONSOLE BOX INSERT  (See REMOVAL )
  68. REMOVE NO. 1 SWITCH HOLE BASE (w/o Smart Key System)  (See REMOVAL )
  69. REMOVE NO. 1 SWITCH HOLE BASE (w/ Smart Key System)  (See REMOVAL )
  70. REMOVE FRONT DOOR SCUFF PLATE RH  (See REMOVAL )
  71. REMOVE COWL SIDE TRIM BOARD RH  (See REMOVAL )
  72. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover)  (See REMOVAL )
  73. REMOVE FRONT NO. 2 CONSOLE BOX INSERT  (See REMOVAL )
  74. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY  (See REMOVAL )
  75. REMOVE CONSOLE BOX CARPET  (See REMOVAL )
  76. REMOVE CONSOLE BOX ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  77. REMOVE CONSOLE BOX ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  78. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY  (See REMOVAL )
  79. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  80. REMOVE SMART KEY ECU ASSEMBLY (w/ Smart Key System)  (See CERTIFICATION ECU )
  81. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY 
    1. Remove the 2 nuts and the No. 1 air duct sub-assembly.
      Fig 3: Locating No 1 Air Duct Sub-Assembly Nuts
      G06015330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Disengage the 6 claws and remove the lower defroster nozzle assembly.
      Fig 4: Removing Lower Defroster Nozzle Assembly And Claws
      G06015331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE 
    1. Remove the 2 bolts and the center instrument panel to cowl brace.
      Fig 5: Locating Center Instrument Panel To Cowl Brace And Bolts
      G06015332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE REAR NO. 2 AIR DUCT (w/ Rear Air Duct) 
    1. Remove the clip.
    2. Turn back the floor carpet.
      Fig 6: Turning Back Floor Carpet
      G06015333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws and remove the rear No. 2 air duct.
      Fig 7: Removing Rear No 2 Air Duct And Claws
      G06015334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE REAR NO. 3 AIR DUCT (w/ Rear Air Duct) 
    1. Remove the clip.
    2. Turn back the floor carpet.
      Fig 8: Turning Back Floor Carpet
      G06015335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws and remove the rear No. 3 air duct.
      Fig 9: Removing Rear No 3 Air Duct And Claws
      G06015336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Manual Air Conditioning System) 
    1. for TMC made:
      1. Disconnect the connector.
      2. Disengage each clamp.
        Fig 10: Locating No 1 Instrument Panel Brace Sub-Assembly And Connector (TMC Made)
        G06015337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for TMMC, NUMMI made:
      1. Disconnect the connector.
      2. Disengage each clamp.
        Fig 11: Locating No 1 Instrument Panel Brace Sub-Assembly And Connector (TMC And NUMMI Made)
        G06015338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
    4. Remove the bolt, the nut, and the No. 1 instrument panel brace sub-assembly.
      Fig 12: Identifying No 1 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      G06015339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Automatic Air Conditioning System) 
    1. for TMC Made:
      1. Disengage each clamp.
        Fig 13: Identifying No 1 Instrument Panel Brace Sub-Assembly And Clamp
        G06015340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for TMMC, NUMMI Made:
      1. Disengage each clamp.
        Fig 14: Identifying No 1 Instrument Panel Brace Sub-Assembly And Clamp
        G06015341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
    4. Remove the bolt, the nut, and the No. 1 instrument panel brace sub-assembly.
      Fig 15: Identifying No 1 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      G06015339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. for TMC Made:
      1. Disengage each clamp.
        Fig 16: Identifying No 2 Instrument Panel Brace Sub-Assembly And Clamp
        G06015343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for TMMC, NUMMI Made:
      1. Disengage each clamp.
        Fig 17: Identifying No 2 Instrument Panel Brace Sub-Assembly And Clamp
        G06015344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
    4. Remove the bolt, the nut, and the No. 2 instrument panel brace sub-assembly.
      Fig 18: Identifying No 2 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      G06015345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE HEATER COVER (w/ Cover) 
    1. Disengage the 4 claws and remove the heater cover.
      Fig 19: Identifying Heater Cover And Claws
      G06015346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct) 
    1. Disengage the 4 claws and remove the rear No. 1 air duct.
  91. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Manual Air Conditioning System) 
    1. Disconnect the connector.
    2. Disengage each clamp and the wire harness.
      Fig 20: Identifying Rear No 1 Air Duct And Claws
      G06015347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 21: Identifying Wire Harness And Clamp
      G06015348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect each connector.
    4. Disengage each clamp.
    5. Remove the 12 bolts, and disengage the wire harness and junction block.
    6. Disengage the cooler drain hose.
      Fig 22: Locating Wire Harness And Junction Block With Bolts
      G06015349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 7 bolts.
      Fig 23: Identifying Instrument Panel Reinforcement Assembly With Bolts
      G06015350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 3 bolts and the instrument panel reinforcement assembly.
      Fig 24: Locating Instrument Panel Reinforcement Assembly And Bolts
      G06015351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Automatic Air Conditioning System) 
    1. Disengage each clamp and the wire harness.
      Fig 25: Identifying Wire Harness And Clamp
      G06015352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector.
    3. Disengage each clamp.
    4. Remove the 12 bolts, and disengage the wire harness and junction block.
    5. Disengage the cooler drain hose.
      Fig 26: Locating Wire Harness And Junction Block And Bolts
      G06015353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 7 bolts.
      Fig 27: Identifying Instrument Panel Reinforcement Assembly With Bolts
      G06015350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and the instrument panel reinforcement assembly.
      Fig 28: Locating Instrument Panel Reinforcement Assembly And Bolts
      G06015351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. REMOVE AIR CONDITIONING UNIT 
    1. Remove the bolt, the nut, and the air conditioning unit.
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    Fig 29: Locating Air Conditioning Unit With Bolt And Nut
    G06015356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY 
    1. Disengage the 2 claws and remove the No. 2 air duct sub-assembly.
      Fig 30: Identifying No 2 Air Duct Sub-Assembly And Claws
      G06015357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. REMOVE BLOWER ASSEMBLY (w/o PTC Heater) 
    1. for Automatic Air Conditioning System:
      1. Disconnect the connector.
    2. Remove the 3 screws and the blower assembly.
      Fig 31: Locating Blower Assembly And Screws
      G06015358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. REMOVE BLOWER ASSEMBLY (w/ PTC Heater) 
    1. Disengage each clamp.
      Fig 32: Identifying Blower Assembly And Clamp
      G06015359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw and disengage the quick heater connector.
    3. for Automatic Air Conditioning System:
      1. Disconnect the connector.
    4. Remove the 3 screws and the blower assembly.
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