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Front Cooling Unit: Removal: Removal

  1. PRECAUTION 

    Refer to PRECAUTION

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  See step  1
  3. POSITION FRONT WHEELS STRAIGHT AHEAD 
  4. REMOVE FRONT WHEEL LH 
  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    WARNING:

    Wait for 90 seconds after disconnecting the cable to prevent the airbag from deploying.

    NOTE:
    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
    • Make sure to select FACE mode before disconnecting the cable from the negative (-) battery terminal.
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to REMOVAL - Step 1
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to REMOVAL - Step 2
  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 4
  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to REMOVAL - Step 5
  10. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 7
  11. DISCONNECT HEATER WATER OUTLET HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.
      Fig 1: Identifying Heater Outlet Water Hose Claws Of Clip
      GTY208443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the heater outlet water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
  12. DISCONNECT HEATER WATER INLET HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater inlet water hose.
      Fig 2: Identifying Heater Inlet Water Hose Claws Of Clip
      GTY208444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the heater inlet water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
  13. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A 
    1. Remove the bolt, and slide the hook connector.
      Fig 3: Sliding Hook Connector
      GTY178548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
      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  . Refer to REMOVAL - Step 5
  16. REMOVE LOWER NO. 2 STEERING WHEEL COVER  . Refer to REMOVAL - Step 6
  17. REMOVE STEERING PAD  . Refer to REMOVAL - Step 7
  18. REMOVE STEERING WHEEL ASSEMBLY  . Refer to REMOVAL - Step 8
  19. REMOVE STEERING COLUMN COVER  . Refer to REMOVAL - Step 10
  20. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  . Refer to REMOVAL - Step 11
  21. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY  . Refer to REMOVAL - Step 12
  22. REMOVE COMBINATION METER ASSEMBLY  . Refer to REMOVAL - Step 5
  23. REMOVE CENTER INSTRUMENT PANEL REGISTER ASSEMBLY  . Refer to REMOVAL - Step 14
  24. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/o Smart Key System)  . Refer to REMOVAL - Step 15
  25. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/ Smart Key System)  . Refer to REMOVAL - Step 16
  26. REMOVE HEATER CONTROL AND ACCESSORY ASSEMBLY (for Manual Air Conditioning System)  . Refer to REMOVAL - Step 3
  27. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System)  . Refer to REMOVAL - Step 3
  28. REMOVE RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System)  . Refer to REMOVAL - Step 6
  29. REMOVE NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System)  . Refer to REMOVAL - Step 6
  30. REMOVE FRONT DOOR SCUFF PLATE LH  . Refer to REMOVAL - Step 20
  31. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH  . Refer to REMOVAL - Step 21
  32. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 23
  33. REMOVE FRONT DOOR SCUFF PLATE RH  . Refer to REMOVAL - Step 29
  34. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH  . Refer to REMOVAL - Step 30
  35. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 26
  36. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 27
  37. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 28
  38. REMOVE LOWER REAR CONSOLE BOX  . Refer to REMOVAL - Step 4
  39. REMOVE CONSOLE BOX ASSEMBLY  . Refer to REMOVAL - Step 5
  40. REMOVE FRONT NO. 1 CONSOLE BOX INSERT  . Refer to REMOVAL - Step 31
  41. REMOVE FRONT NO. 2 CONSOLE BOX INSERT  . Refer to REMOVAL - Step 32
  42. REMOVE POWER SWITCH (w/ Smart Key System)  . Refer to REMOVAL - Step 11
  43. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH  . Refer to REMOVAL - Step 22
  44. REMOVE FRONT PILLAR GARNISH LH  . Refer to REMOVAL - Step 23
  45. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH  . Refer to REMOVAL - Step 31
  46. REMOVE FRONT PILLAR GARNISH RH  . Refer to REMOVAL - Step 32
  47. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 38
  48. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)  . Refer to REMOVAL - Step 4
  49. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 40
  50. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)  . Refer to REMOVAL - Step 41
  51. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY  . Refer to REMOVAL - Step 4
  52. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY  . Refer to REMOVAL - Step 43
  53. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY  . Refer to REMOVAL - Step 8
  54. REMOVE BRAKE PEDAL RETURN SPRING  . Refer to REMOVAL - Step 2
  55. REMOVE STOP LIGHT SWITCH ASSEMBLY  . Refer to REMOVAL - Step 4
  56. REMOVE PUSH ROD PIN  . Refer to REMOVAL - Step 4
  57. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY  . Refer to REMOVAL - Step 6
  58. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY  . Refer to REMOVAL - Step 12
  59. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  . Refer to REMOVAL - Step 13
  60. REMOVE STEERING COLUMN ASSEMBLY  . Refer to REMOVAL - Step 14
  61. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 
    1. Remove the 3 nuts and disconnect the instrument panel junction block assembly.
      Fig 4: Identifying Instrument Panel Junction Block Assembly Nuts
      GTY170424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE POWER STEERING ECU ASSEMBLY  . Refer to REMOVAL - Step 11
  63. REMOVE CERTIFICATION ECU (SMART KEY ECU ASSEMBLY)  . Refer to REMOVAL - Step 5
  64. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY  See step  6
  65. REMOVE REAR NO. 1 AIR DUCT 
    1. Disengage the claw.
      Fig 5: Identifying Floor Carpet & Claw
      GTY173298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the floor carpet as shown in the illustration.
    3. Remove the clip.
      Fig 6: Identifying Rear No. 1 Air Duct Claws
      GTY177367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the clamp.
    5. Disengage the 2 claws and remove the rear No. 1 air duct.
  66. REMOVE REAR NO. 3 AIR DUCT 
    1. Disengage the claw.
      Fig 7: Identifying Floor Carpet & Claw
      GTY178207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the floor carpet as shown in the illustration.
    3. Remove the clip.
      Fig 8: Identifying Rear No. 3 Air Duct Claws
      GTY189108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 claws and remove the rear No. 3 air duct.
  67. REMOVE CENTER HEATER TO REGISTER DUCT 
    1. Disengage the clamp.
      Fig 9: Identifying Center Heater To Register Duct Claws
      GTY208032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 4 claws and remove the center heater to register duct.
  68. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the earth wire.
      Fig 10: Locating Earth Wire Bolt
      GTY184105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage each clamp.
    3. Remove the 2 bolts.
      Fig 11: Identifying No. 1 Instrument Panel Brace Sub-Assembly Nuts
      GTY184301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the screw.
    5. Remove the 3 nuts and the No. 1 instrument panel brace sub-assembly.
  69. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the earth wire.
      Fig 12: Locating Earth Wire Bolt
      GTY208033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage each clamp.
    3. Remove the bolt.
      Fig 13: Identifying No. 2 Instrument Panel Brace Sub-Assembly Nuts & Bolts
      GTY190556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the screw.
    5. Remove the 3 nuts and the No. 2 instrument panel brace sub-assembly.
  70. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT 
    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 Instrument Panel Reinforcement Assembly Connectors
      GTY208037Courtesy 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 15: Identifying Engine Compartment Side Caps & Bolts
      GTY183763Courtesy 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 16: Identifying Collars & Instrument Panel Reinforcement Assembly
      GTY208038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE AIR CONDITIONING UNIT 
    1. Remove the 3 bolts and the air conditioning unit from the instrument panel reinforcement assembly.
      Fig 17: Identifying Air Conditioning Unit Bolts
      GTY208040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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