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Instrument Panel ASSY Lower: Replacement

HINT:

  1. TABLE OF BOLT, SCREW AND NUT 

    HINT:

    The bolts, screws and nuts necessary for installation and removal of the instrument panel, are illustrated in Fig 1 and alphabetically coded.

    Fig 1: Instrument Panel Assy Lower Bolts, Screws And Nuts Table
    G03097647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE  PRECAUTION  ) 
  3. REMOVE INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY (SEE  INSTRUMENT PANEL SUB-ASSY  ) 
  4. REMOVE HORN BUTTON ASSY (SEE  REPLACEMENT  ) 
  5. REMOVE STEERING WHEEL ASSY (SEE  OVERHAUL  ) 

    SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

  6. REMOVE STEERING COLUMN COVER (SEE  OVERHAUL  ) 
  7. REMOVE HEADLAMP DIMMER SWITCH ASSY (SEE  REPLACEMENT  ) 
  8. REMOVE WINDSHIELD WIPER SWITCH ASSY (SEE  REPLACEMENT  ) 
  9. REMOVE FRONT DOOR SCUFF PLATE LH (SEE  REPLACEMENT  ) 
  10. REMOVE FRONT DOOR SCUFF PLATE RH (SEE  REPLACEMENT  ) 
  11. REMOVE COWL SIDE TRIM BOARD LH (SEE  REPLACEMENT  ) 
  12. REMOVE COWL SIDE TRIM BOARD RH (SEE  REPLACEMENT  ) 
  13. REMOVE HEATER CONTROL & ACCESSORY ASSY (SEE  REPLACEMENT  ) 
  14. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY LOWER CENTER 
    1. Disengage the 2 claws and the 2 clips.
      Fig 2: Locating Instrument Cluster Finish Panel Sub-Assembly Lower Center Claws And Clips
      G03097648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connectors, and then remove the instrument cluster finish panel sub-assy lower center.
  15. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER 
    1. Using a clip remover, remove the clip.
    2. Disengage the 3 claws, and remove the instrument panel finish panel lower center.
      Fig 3: Locating Instrument Panel Finish Panel Lower Center Claws
      G03097649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE GLOVE COMPARTMENT DOOR ASSY 
    1. Push the right side wall, and then push the left wall to release the stoppers.
      Fig 4: Releasing Glove Compartment Door Assembly Stoppers
      G03097650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull the glove compartment door assy rearward to remove it.
      Fig 5: Removing Glove Compartment Door Assembly
      G03097651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE SHIFT LEVER KNOB SUB-ASSY (M/T TRANSAXLE) 
  18. REMOVE CONSOLE BOX ASSY REAR 
    1. Disengage the 4 claws, and remove the console box rear cover.
    2. Remove the console box carpet.
    3. Remove the screw < K >.
    4. Disengage the 2 clips, and remove the console box assy rear.
      Fig 6: Removing Console Box Assembly Rear
      G03097652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (A/T TRANSAXLE) (SEE  OVERHAUL  ) 
  20. REMOVE STEERING COLUMN HOLE COVER PLATE (SEE  OVERHAUL  ) 
  21. DISCONNECT STEERING INTERMEDIATE SHAFT ASSY (SEE  OVERHAUL  ) 
  22. REMOVE STEERING INTERMEDIATE SHAFT ASSY (SEE  OVERHAUL  ) 
  23. REMOVE STEERING COLUMN ASSY (SEE  OVERHAUL  ) 
  24. REMOVE ANTENNA CORD SUB-ASSY 
  25. REMOVE INSTRUMENT PANEL ASSY LOWER W/INSTRUMENT PANEL REINFORCEMENT 
    1. Remove the 3 bolts < A >.
      Fig 7: Locating Bolts
      G03097653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts < A >.
      Fig 8: Locating Bolts
      G03097654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a clip remover, remove the clip.
      Fig 9: Removing Clip
      G03097655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt < A > and 2 bolts < L >.
      Fig 10: Removing Bolts
      G03097656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt < L > and the instrument panel mounting bracket No. 1.
      Fig 11: Removing Bolt
      G03097657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the screw < I >.
      Fig 12: Locating Screw
      G03097658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the connector, and remove the door control receiver.
    8. Remove the bolt < A >.
      Fig 13: Removing Bolt
      G03097659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect the hood look control cable.
    10. Remove the 2 bolts < H >, the 2 nuts < M > and the 2 screws < I > or < J >.
    11. Remove the 2 screws < D > and 3 nuts < M >, and separate the instrument panel junction block assy.
    12. Disconnect the connectors, and then remove the instrument panel assy lower w/instrument panel reinforcement.
      Fig 14: Locating Instrument Panel Assembly Lower W/Instrument Panel Reinforcement Bolts, Nuts And Screws
      G03097660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Using a clip remover, remove the 2 clips.
      Fig 15: Removing Instrument Panel Reinforcement Clips
      G03097661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw < D >.
      Fig 16: Locating Screw
      G03097662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts < H > and the instrument panel LWR pad insert LH.
      Fig 17: Removing Instrument Panel LWR Pad Insert LH Bolts
      G03097663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and the instrument panel brace sub-assy No. 1.
      Fig 18: Removing Nut And Instrument Panel Brace Sub-Assembly No. 1
      G03097664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FUSE BOX OPENING COVER 
  28. REMOVE HEATER TO REGISTER DUCT NO. 2 
    1. Using nippers etc., cut off the ultrasonic welding portion as shown in Fig 19 and Fig 20 to remove the heater to register duct No. 2 from the instrument panel sub-assy.
      Fig 19: Locating Ultrasonic Welding Portions
      G03097665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 20: Identifying Ultrasonic Welding Portion, Cut Line And Heater To Register Duct No. 2
      G03097666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE INSTRUMENT PANEL BRACKET SUB-ASSY CENTER 
    1. Remove the screw < D > and the instrument panel bracket sub-assy center.
      Fig 21: Locating Instrument Panel Bracket Sub-Assembly Center Screw
      G03097667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE INSTRUMENT PANEL HOLE COVER 
  31. REMOVE INSTRUMENT PANEL ASSY LOWER 
  32. INSTALL HEATER TO REGISTER DUCT NO. 2 
    1. When replacing the instrument panel sub-assy lower with a new one, cut the boss off using nippers, etc. as shown in Fig 22.
      NOTE: When reusing the instrument panel sub-assy lower, start from step  b.
      Fig 22: Cutting Boss Off Heater To Register Duct No. 2
      G03097668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screw, install the heater to register duct No. 2.
      Fig 23: Installing Heater To Register Duct No. 2
      G03097669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL STEERING COLUMN ASSY (SEE  OVERHAUL  ) 
  34. INSTALL STEERING INTERMEDIATE SHAFT ASSY (SEE  OVERHAUL  ) 
  35. CONNECT STEERING INTERMEDIATE SHAFT ASSY (SEE  OVERHAUL  ) 
  36. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY (A/T TRANSAXLE) (SEE  OVERHAUL  ) 
  37. INSTALL INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY (SEE  INSTRUMENT PANEL SUB-ASSY  ) 
  38. ADJUST SPIRAL CABLE SUB-ASSY (SEE  REPLACEMENT  ) 
  39. INSTALL STEERING WHEEL ASSY (SEE  OVERHAUL  ) 
  40. INSTALL HORN BUTTON ASSY (SEE  REPLACEMENT  ) 
  41. INSPECT HORN BUTTON ASSY (SEE  ON-VEHICLE INSPECTION  ) 
  42. INSPECT SRS WARNING LIGHT (SEE  DIAGNOSIS SYSTEM  ) 
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