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Home >> Toyota >> 2018 >> Prius Two Eco >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System - Service Information (1 Of 2) >> Air Conditioning Unit >> Removal [11/2015 - 11/2017] >> Procedure

Removal [11/2015 - 11/2017]: Procedure

  1. PRECAUTION 
    NOTE:
    • Make sure to select face mode before disconnecting the cable from the negative (-) auxiliary battery terminal.
    • Make sure to perform initialization after replacing the air conditioning radiator damper servo sub-assembly. If initialization is not performed, the air conditioner unit assembly will not perform properly as the air conditioning amplifier assembly will not be able to recognize the position of the air conditioning radiator damper sub-assembly.
  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    See step  1

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  5. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  8. DISCONNECT OUTLET HEATER WATER HOSE A (w/o Exhaust Heat Recirculation System) 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet heater water hose A.
      GTY562736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the outlet heater water hose A.
      • Prepare a drain pan or cloth in case the coolant leaks.
  9. DISCONNECT WATER PIPE AND HOSE SUB-ASSEMBLY A (w/ Exhaust Heat Recirculation System) 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the water pipe and hose sub-assembly A.
      GTY562739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the water pipe and hose sub-assembly A.
      • Prepare a drain pan or cloth in case the coolant leaks.
  10. DISCONNECT INLET HEATER WATER HOSE A 
    1. w/o Exhaust Heat Recirculation System:
      1. Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose A.
        GTY562734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Do not apply excessive force to the inlet heater water hose A.
        • Prepare a drain pan or cloth in case the coolant leaks.
    2. w/ Exhaust Heat Recirculation System:
      1. Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose A.
        GTY562732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Do not apply excessive force to the inlet heater water hose A.
        • Prepare a drain pan or cloth in case the coolant leaks.
  11. DISCONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the bolt and rotate the hook connector as shown in the illustration.
      GTY562720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the suction pipe sub-assembly.
      GTY562712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the suction pipe sub-assembly.
      NOTE:

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

  12. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Disconnect the air conditioner tube and accessory assembly.
      GTY562714Courtesy 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.

  13. REMOVE FRONT SEAT ASSEMBLY LH 

    for Manual seat:

    Refer to REMOVAL [11/2015 - 12/2018]

    for Power seat:

    Refer to REMOVAL [11/2015 - 12/2018]

  14. REMOVE FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to REMOVAL [11/2015 - 12/2018]

  15. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY 

    Refer to REMOVAL [11/2015 - 11/2017]

  16. REMOVE STEERING COLUMN ASSEMBLY 

    Refer to REMOVAL [11/2015 - 12/2018]

  17. REMOVE SKID CONTROL BUZZER (w/ Toyota Safety Sense P) 

    Refer to PROCEDURE - Step 2

  18. REMOVE DRIVING SUPPORT ECU ASSEMBLY (w/ Toyota Safety Sense P) 

    Refer to PROCEDURE - Step 2

  19. REMOVE WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor) 

    Refer to PROCEDURE - Step 2

  20. REMOVE NO. 1 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System) 

    Refer to PROCEDURE - Step 2

  21. REMOVE NO. 2 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System) 

    Refer to PROCEDURE - Step 3

  22. REMOVE CLEARANCE WARNING ECU ASSEMBLY (w/ TOYOTA Parking Assist-sensor System) 

    Refer to PROCEDURE - Step 3

  23. REMOVE BACK-UP BATTERY WITH BRACKET (w/ Manual (SOS) Switch) 

    Refer to PROCEDURE - Step 2

  24. REMOVE ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 5

  25. REMOVE SHIFT LOCK CONTROL UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 15

  26. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.
      GTY562700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT NO. 1 CONSOLE BOX INSERT 
    1. Disengage the clip and claw as shown in the illustration.
      GTY554308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    2. Disengage the guide to remove the front No. 1 console box insert as shown in the illustration.
      GTY546709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  28. REMOVE FRONT NO. 2 CONSOLE BOX INSERT 
    1. Disengage the clip and claw as shown in the illustration.
      GTY588472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    2. Disengage the guide to remove the front No. 2 console box insert as shown in the illustration.
      GTY593790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  29. REMOVE FRONT FLOOR CAUTION PLATE COVER 
    1. Disengage the claw and guide as shown by the arrow (1), and then pull the front floor caution plate cover as shown by the arrow (2) in the illustration to remove it.
      GTY739843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction (1)
      Remove in this Direction (2)

      HINT: 

      When replacing a type A front floor carpet assembly with a type B front floor carpet assembly, it is not necessary to remove the front floor caution plate cover.

      GTY1025854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
  30. REMOVE REAR NO. 3 AIR DUCT 
    1. Remove the 2 front floor carpet clips.
      GTY543852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 guides and turn back the front floor carpet assembly as shown in the illustration.
      GTY553263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws to remove the rear No. 3 air duct as shown in the illustration.
      GTY582221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  31. REMOVE REAR NO. 2 AIR DUCT 
    1. Disengage the 2 claws and remove the rear No. 2 air duct.
      GTY553248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR NO. 5 AIR DUCT 
    1. GTY543850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 front floor carpet clips.

    2. Disengage the 2 guides and turn back the front floor carpet assembly as shown in the illustration.
      GTY553259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws to remove the rear No. 5 air duct as shown in the illustration.
      GTY573786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  33. REMOVE REAR NO. 4 AIR DUCT 
    1. GTY600769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 2 claws and remove the rear No. 4 air duct.

  34. REMOVE REAR NO. 1 AIR DUCT 
    1. GTY553232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 4 claws to remove the rear No. 1 air duct.

  35. REMOVE NO. 3 DASH PANEL INSULATOR PAD 
    1. Cut each claw of the 2 clips and remove the No. 3 dash panel insulator pad.
      GTY772228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cut
      NOTE:

      If the No. 3 dash panel insulator pad is damaged, replace it with a new one.

    2. Remove the 2 clips.
  36. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Turn back the front floor mat as shown in the illustration.
      GTY604438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage each clamp.
      GTY569627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and disconnect the earth wire.
    4. Remove the bolt, screw, nut and No. 1 instrument panel brace sub-assembly.
      GTY609620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  37. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Turn back the front floor mat as shown in the illustration.
      GTY569621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage each clamp.
      GTY604436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, screw, nut and No. 2 instrument panel brace sub-assembly.
      GTY579887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  38. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 
    1. Disengage the clamp and 2 claws to disconnect the DLC3 connector.
      GTY588455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Remove the bolt, nut and No. 3 instrument panel to cowl brace sub-assembly.
  39. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 3

  40. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Disengage the 6 claws to remove the lower defroster nozzle assembly.
      GTY558595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioner unit assembly when removing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
    • When disassembling the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. Disconnect each connector.
      GTY579646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Earth Wire *b Relay Block Assembly
      Connector Bolt
    2. Remove the 3 bolts and disconnect the 3 earth wires.
    3. Remove the bolt and disconnect the relay block assembly.
    4. Disengage each clamp and disconnect the instrument panel wire.
    5. Disconnect the drain cooler hose.
      GTY539004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 COOLER UNIT DRAIN HOSE GROMMET
      NOTE:

      If the cooler unit drain hose grommet is disconnected from the vehicle body while disconnecting the drain cooler hose, make sure to replace it with a new one. Failure to do so may cause water ingress.

    6. Remove the 2 bolts.
      GTY558606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 4 bolts (A).
      GTY550485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A) Bolt (B)
      Nut - -
    8. Remove the bolt (B) and disconnect the parking brake pedal assembly.
    9. Remove the nut.
    10. Disconnect each connector.
      GTY595305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
    11. Remove the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.
    12. Disengage the claw and 2 guides and disconnect the ID code box (immobiliser code ECU) as shown in the illustration.
      GTY603917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  42. REMOVE AIR CONDITIONER UNIT ASSEMBLY 
    1. Remove the 3 bolts and air conditioner unit assembly from the instrument panel reinforcement assembly.
      GTY604318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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