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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System (Service Information) (Hybrid) >> Front Air Conditioning Unit >> Removal [11/2016 - ] >> Procedure

Removal [11/2016 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    Make sure to select face mode before disconnecting the cable from the negative (-) auxiliary battery terminal.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    See step  1

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  5. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the bolt and rotate the hook connector as shown in the illustration.
      GTY455354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the suction hose sub-assembly.
      GTY446674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  6. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Disconnect the air conditioner tube and accessory assembly.
      GTY455372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the air conditioner tube and accessory assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  7. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet heater water hose.
      GTY446753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the outlet heater water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
  8. DISCONNECT INLET HEATER WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose.
      GTY446752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the inlet heater water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
  9. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) 

    Refer to REMOVAL [11/2016 - ]

  10. REMOVE FRONT SEAT ASSEMBLY LH (for Power Seat) 

    Refer to REMOVAL [02/2014 - ]

  11. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) 

    HINT: 

    Use the same procedure as for the LH side.

  12. REMOVE FRONT SEAT ASSEMBLY RH (for Power Seat) 

    HINT: 

    Use the same procedure as for the LH side.

  13. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  14. REMOVE STEERING POST ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  15. REMOVE ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 11

  16. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 

    See step  12

  17. REMOVE HYBRID VEHICLE CONTROL ECU ASSEMBLY 

    Refer to PROCEDURE - Step 12

  18. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 13

  19. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Disengage the 3 clamps.
      GTY440437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and wire harness clamp bracket.
  20. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.
      GTY428601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR NO. 2 AIR DUCT 
    1. Disengage 4 guides and 2 fasteners, and turn back the front floor carpet assembly as shown in the illustration.
      GTY439711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fastener
    2. Remove the clip and rear No. 2 air duct.
      GTY440433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR NO. 1 AIR DUCT 
    1. Disengage the clamp to disconnect the wire harness.
      GTY440434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws and remove the rear No. 1 air duct.
  23. REMOVE REAR NO. 4 AIR DUCT 
    1. Disengage the 4 guides and fastener, and turn back the front floor carpet assembly as shown in the illustration.
      GTY441574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fastener
    2. Remove the clip and rear No. 4 air duct.
      GTY454009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR NO. 3 AIR DUCT 
    1. Disengage the 2 claws and remove the rear No. 3 air duct.
      GTY440425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  26. REMOVE SHIFT LEVER SUPPORT 
    1. Disconnect each connector.
    2. Disengage each clamp.
      GTY429458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt
    3. Remove the 2 nuts, 4 bolts and shift lever support.
  27. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Disengage each clamp.
      GTY432419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Earth Wire
    2. Remove the bolt and disconnect the earth wire.
    3. Turn back the No. 3 front floor silencer.
    4. Remove the 2 bolts, screw, 2 nuts and No. 1 instrument panel brace sub-assembly.
      GTY436385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  28. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Disengage each clamp.
      GTY440428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the No. 3 front floor silencer.
    3. Remove the bolt, screw, 2 nuts and No. 2 instrument panel brace sub-assembly.
      GTY439307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  29. REMOVE INSTRUMENT PANEL SAFETY PAD CAP 
    1. Put protective tape around the 4 instrument panel safety pad caps.
      GTY441897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for LH Side
      *B for RH Side
      Protective Tape
    2. Using a screwdriver, remove the 4 instrument panel safety pad caps.
  30. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT 
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it. Failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When disassembling the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. Remove the 4 bolts and disconnect the 4 earth wires.
      GTY441727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Earth Wire - -
    2. Disconnect each connector.
    3. Disengage each clamp.
    4. Remove the 2 hole plugs.
      GTY446757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 bolts.
      GTY446761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the claw and disconnect the drain cooler hose from the piping clamp.
      GTY440416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 hole plugs.
      GTY438621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for LH Side
      *B for RH Side
    8. Disconnect the drain cooler hose.
      GTY451343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Vehicle Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
      Nut Bolt
    9. Remove the nut and 6 bolts as shown in the illustration.
    10. Disengage the 3 guides and remove the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.
      GTY440420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE AIR CONDITIONING UNIT ASSEMBLY 
    1. Remove the 3 bolts.
      GTY440401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws to remove the air conditioning unit assembly from the instrument panel reinforcement assembly.
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