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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System (Service Information) (Except Hybrid) (1 Of 2) >> Front Air Conditioning Unit >> Removal [11/2016 - ] >> Procedure

Removal [11/2016 - ]: Procedure

  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    See step  1

  2. REMOVE FRONT WIPER ARM HEAD CAP 

    Refer to PROCEDURE - Step 1

  3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH 

    Refer to PROCEDURE - Step 3

  5. REMOVE FRONT FENDER TO COWL SIDE SEAL LH 

    Refer to PROCEDURE - Step 4

  6. REMOVE FRONT FENDER TO COWL SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  7. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 2GR-FKS) 

    Refer to REMOVAL [12/2013 - ]

  9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2GR-FKS) 

    Refer to PROCEDURE - Step 4

  10. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the bolt and rotate the hook connector.
      GTY454014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the suction hose sub-assembly.
      GTY440444Courtesy 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.

  11. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Disconnect the air conditioner tube and accessory assembly.
      GTY440443Courtesy 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.

  12. 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.
      NOTE:
      • Do not apply excessive force to the outlet heater water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
      GTY440439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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.
      GTY454013Courtesy 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.
  14. REMOVE FRONT SEAT ASSEMBLY LH (for Manual Seat) 

    Refer to REMOVAL [12/2013 - ]

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

    Refer to REMOVAL [12/2013 - ]

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

    HINT: 

    Use the same procedure as for the LH side.

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

    HINT: 

    Use the same procedure as for the LH side.

  18. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  19. REMOVE STEERING POST ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  20. REMOVE ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) 

    Refer to PROCEDURE - Step 8

  21. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 

    Refer to PROCEDURE - Step 10

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

    Refer to PROCEDURE - Step 10

  23. 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.
  24. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System) 
    1. Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.
      GTY428601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. 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
  26. 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.
  27. 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
  28. 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
  29. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY 

    for U760E Automatic Transmission / Transaxle:

    Refer to REMOVAL [12/2013 - ]

    for UA80E Automatic Transmission / Transaxle:

    Refer to REMOVAL [11/2016 - ]

    for UA80F Automatic Transmission / Transaxle:

    Refer to REMOVAL [11/2016 - ]

  30. 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.
  31. 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. Remove the 2 bolts, screw, 2 nuts and No. 1 instrument panel brace sub-assembly.
      GTY436385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  32. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Disengage each clamp.
      GTY440428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, screw, 2 nuts and No. 2 instrument panel brace sub-assembly.
      GTY439307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  33. 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.
  34. 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.
      GTY440412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 bolts.
      GTY440417Courtesy 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
    11. w/ Engine Immobilizer System:
      1. Disengage the claw and 2 guides to disconnect the transponder key ECU assembly as shown in the illustration.
        GTY440404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. 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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