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Front Cooling Unit: Removal

  1. PRECAUTION 

    (See INSTRUMENT PANEL SAFETY PAD )

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  (See REPLACEMENT )
  3. POSITION FRONT WHEELS STRAIGHT AHEAD 
  4. REMOVE FRONT WHEEL LH 
  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag from deploying (See AIRBAG SYSTEM ).
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY 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 PANEL SUB-ASSEMBLY  (See REMOVAL )
  11. DISCONNECT HEATER WATER HOSE OUTLET 
    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 1: Identifying Heater Outlet Water Hose And Clip
    G06119076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT HEATER WATER HOSE INLET 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.
    NOTE:
    • Do not apply excessive force to the heater inlet water hose.
    • Prepare a drain pan or cloth in case the coolant leaks.
    Fig 2: Identifying Heater Inlet Water Hose And Clip
    G06119077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A 
    1. Remove the bolt, and slide the hook connector.
    2. (b). Disconnect the cooler refrigerant liquid pipe A.
    3. Remove the O-ring from the cooler refrigerant liquid pipe A.
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
  14. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION PIPE 
    1. Disconnect the No. 1 cooler refrigerant suction pipe.
    2. Remove the O-ring from the No. 1 cooler refrigerant suction pipe.
    Fig 3: Identifying Cooler Refrigerant Liquid Pipe A And Bolt
    G06119078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
  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 DISASSEMBLY )
  19. REMOVE STEERING COLUMN COVER  (See REMOVAL )
  20. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  (See REMOVAL )
  21. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY  (See REMOVAL )
  22. REMOVE COMBINATION METER ASSEMBLY  (See REMOVAL )
  23. REMOVE CENTER INSTRUMENT PANEL REGISTER ASSEMBLY  (See REMOVAL )
  24. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/o Smart Key System)  (See REMOVAL )
  25. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/ Smart Key System)  (See REMOVAL )
  26. REMOVE HEATER CONTROL AND ACCESSORY ASSEMBLY (for Manual Air Conditioning System)  (See AIR CONDITIONING PANEL (FOR MANUAL AIR CONDITIONING SYSTEM) )
  27. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System)  (See REMOVAL )
  28. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System)  (See REMOVAL )
  29. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System)  (See REMOVAL )
  30. REMOVE FRONT DOOR SCUFF PLATE LH  (See REMOVAL )
  31. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH  (See REMOVAL )
  32. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Manual Air Conditioning System)  (See REMOVAL )
  33. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Automatic Air Conditioning System)  (See REMOVAL )
  34. REMOVE FRONT DOOR SCUFF PLATE RH  (See REMOVAL )
  35. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH  (See REMOVAL )
  36. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See REMOVAL )
  37. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  38. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY  (See REMOVAL )
  39. REMOVE NO. 2 CONSOLE BOX DUCT (w/o Rear Air Conditioning System)  (See REMOVAL )
  40. REMOVE LOWER REAR CONSOLE BOX  (See REMOVAL )
  41. REMOVE CONSOLE BOX ASSEMBLY (w/o Rear Air Conditioning System)  (See REMOVAL )
  42. REMOVE CONSOLE BOX ASSEMBLY (w/ Rear Air Conditioning System)  (See DISASSEMBLY )
  43. REMOVE FRONT NO. 1 CONSOLE BOX INSERT  (See REMOVAL )
  44. REMOVE FRONT NO. 2 CONSOLE BOX INSERT  (See REMOVAL )
  45. REMOVE ENGINE SWITCH (w/ Smart Key System)  (See INSPECTION )
  46. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See REMOVAL )
  47. REMOVE FRONT PILLAR GARNISH LH  (See REMOVAL )
  48. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See REMOVAL )
  49. REMOVE FRONT PILLAR GARNISH RH  (See REMOVAL )
  50. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See REMOVAL )
  51. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)  (See REMOVAL )
  52. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See REMOVAL )
  53. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)  (See REMOVAL )
  54. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY  (See REMOVAL )
  55. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for Pole Antenna Type)  (See REMOVAL )
  56. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for Glass Antenna Type)  (See REMOVAL )
  57. REMOVE BRAKE PEDAL RETURN SPRING  (See REMOVAL )
  58. REMOVE STOP LIGHT SWITCH ASSEMBLY  (See INSPECTION )
  59. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS  (See REMOVAL )
  60. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY  (See REMOVAL )
  61. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY  (See REMOVAL )
  62. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY  (See REMOVAL )
  63. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See REMOVAL )
  64. REMOVE STEERING COLUMN ASSEMBLY  (See REMOVAL )
    Fig 4: Identifying Nuts And Instrument Panel Junction Block Assembly
    G06119079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 
    1. Remove the 3 nuts and disconnect the instrument panel junction block assembly.
  66. REMOVE POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
  67. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/ Smart Key System)  (See REMOVAL )
  68. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY  (See REMOVAL )
  69. REMOVE REAR NO. 1 AIR DUCT 
    1. Disengage the claw.
    2. Turn back the floor carpet as shown in the illustration.
      Fig 5: Identifying Floor Carpet Claw
      G06119080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the clip.
    4. Disengage the clamp.
    5. Disengage the 2 claws and remove the rear No. 1 air duct.
    Fig 6: Identifying Claws And Rear No. 1 Air Duct
    G06119081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE REAR NO. 3 AIR DUCT 
    1. Disengage the claw.
    2. Turn back the floor carpet as shown in the illustration.
      Fig 7: Identifying Floor Carpet Claw
      G06119082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the clip.
    4. Disengage the 2 claws and remove the rear No. 3 air duct.
    Fig 8: Identifying Rear No. 3 Air Duct Claws And Clip
    G06119083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE NO. 1 CONSOLE BOX DUCT (w/o Rear Air Conditioning System) 
    1. Remove the clip and the No. 1 console box duct.
    Fig 9: Identifying Clip And No. 1 Console Box Duct
    G06119084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE CENTER HEATER TO REGISTER DUCT 
    1. Disengage the clamp.
    2. Disengage the 4 claws and remove the center heater to register duct.
    Fig 10: Identifying Claws And Center Heater To Register Duct
    G06119085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the earth wire.
    2. Disengage each clamp.
      Fig 11: Locating Earth Wire Bolt
      G06119086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts.
    4. Remove the screw.
    5. Remove the 3 nuts and the No. 1 instrument panel brace sub-assembly.
    Fig 12: Identifying No. 1 Instrument Panel Brace Sub-Assembly Screw, Nuts And Bolts
    G06119087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the earth wire.
    2. Disengage each clamp.
      Fig 13: Locating Earth Wire Bolt
      G06119088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt.
    4. Remove the screw.
    5. Remove the 3 nuts and the No. 2 instrument panel brace sub-assembly.
  75. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/o PTC Heater) 
    1. Disengage each clamp.
    2. Remove the 2 bolts and disconnect the 2 earth wires.
    3. Disconnect each connector.
    4. Remove the 2 nuts and bolt.
    5. Disconnect the blower motor connector.
      Fig 14: Identifying No. 2 Instrument Panel Brace Sub-Assembly Screw, Nuts And Bolt
      G06119089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 15: Identifying Blower Motor Connector, Nuts And Bolt
      G06119090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 caps and the 2 bolts from the engine compartment side.
    7. Disconnect the cooler drain hose.
    8. Remove the nut.
      Fig 16: Identifying Engine Compartment Side Caps And Bolts
      G06119091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. 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.

    10. Using a 12 mm hexagon wrench, remove the 2 collars and the instrument panel reinforcement assembly with air conditioning unit.
    11. Disconnect the connector.
    Fig 17: Identifying Passenger Side TORX Bolts
    G06119092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/ PTC Heater) 
    1. Disengage each clamp.
    2. Remove the 2 bolts and disconnect the 2 earth wires.
    3. Disconnect each connector.
    4. Remove the 2 nuts and bolt.
    5. Disconnect the blower motor connector.
    6. Disconnect the 2 quick heater connectors.
      Fig 18: Identifying Blower Motor Connector, Nuts And Bolt
      G06119093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 caps and the 2 bolts from the engine compartment side.
    8. Disconnect the cooler drain hose.
    9. Remove the nut.
      Fig 19: Identifying Engine Compartment Side Caps And Bolts
      G06119094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. 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.

    11. Using a 12 mm hexagon wrench, remove the 2 collars and the instrument panel reinforcement assembly with air conditioning unit.
    12. Disconnect the connector.
      Fig 20: Identifying TORX Bolts On Passenger Side
      G06119095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE AIR CONDITIONING UNIT 
    1. Remove the 3 bolts and the air conditioning unit from the instrument panel reinforcement assembly.
    Fig 21: Identifying Air Conditioning Unit Bolts
    G06119096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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