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Air Conditioning Unit: Removal

  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REPLACEMENT   ) 
  2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 
    1. Install SST to the piping clamp.

      SST 09870-00015 

      HINT:

      Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. See Fig 1.

      Fig 1: Installing SST On Piping Clamp
      G05195318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down SST and release the clamp lock.
      NOTE: Be careful not to deform the tube when pushing SST.
    3. Pull SST slightly and push the release lever, then remove the piping clamp with SST.
    4. Remove the piping clamp from SST.
      Fig 2: Removing Piping Clamp From SST
      G04966028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the cooler refrigerant suction hose No. 1.
      NOTE:
      • Do not use tools like a screwdriver to remove the tube.
      • Cap the open fittings immediately to keep moisture or dirt out of the system.
  3. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY SST 09870-00015 

    HINT:

    Disconnect in the same way as the cooler refrigerant suction hose No. 1.

    Fig 3: Identifying Cooler Refrigerant Suction Hose No. 1
    G05236211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT HEATER INLET WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip and disconnect the heater inlet water hose.
  5. DISCONNECT HEATER OUTLET WATER HOSE 

    HINT:

    Disconnect in the same way as the heater inlet water hose.

    Fig 4: Identifying Heater Inlet Water Hose
    G05195321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY (See  REMOVAL  ) 
  7. REMOVE INSTRUMENT PANEL LOWER PAD INSERT LH 
    1. Remove the 3 screws and instrument panel lower pad insert LH.
  8. REMOVE INSTRUMENT PANEL LOWER MOUNT BRACKET NO. 1 
    Fig 5: Identifying Instrument Panel Lower Pad Insert LH
    G05236213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO. 1 
    1. Remove the 2 clips and take up the floor carpet.

      HINT:

      Take up the floor carpet as small as the instrument panel brace sub-assembly No. 1 can be removed.

      Fig 6: Removing Clips At Floor Carpet
      G05236214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 clamps and floor shift parking lock cable assembly.
      Fig 7: Identifying Clamps And Floor Shift Parking Lock Cable Assembly
      G05236215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
    4. Remove the bolt, nut and instrument panel brace sub-assembly No. 1.
      Fig 8: Identifying Instrument Panel Brace Sub-Assembly No. 1
      G05236216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO. 2 
    1. Remove the 2 clips and take up the floor carpet.

      HINT:

      Take up the floor carpet as small as the instrument panel brace sub-assembly No. 2 can be removed.

      Fig 9: Removing Clips From Floor Carpet
      G05236217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and instrument panel brace sub-assembly No. 2.
      Fig 10: Identifying Instrument Panel Brace Sub-Assembly No. 2
      G05236218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE AIR DUCT NO. 1 
    1. Release the 2 fitting claws and remove the air duct No. 1.
      Fig 11: Identifying Air Duct No. 1 With Claws
      G05195326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE AIR DUCT NO. 2 
    1. Remove the screw.
    2. Release the 2 fitting claws and remove the air duct No. 2.
      Fig 12: Identifying Air Duct No. 2 With Claws
      G05195327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE AIR DUCT REAR NO. 3 (for Cold Area Specification Vehicles) 
    1. Release the 6 fitting claws and remove the air duct rear No. 3.
      Fig 13: Identifying Air Duct Rear No. 3 With Claws
      G05236221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE AIR DUCT REAR NO. 4 (for Cold Area Specification Vehicles) 
    1. Release the 6 fitting claws and remove the air duct rear No. 4.
      Fig 14: Identifying Air Duct Rear No. 4 With Claws
      G05236222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE HEATER TO REGISTER DUCT NO. 1 
    1. Remove the 2 clips and heater to register duct No. 1.
      Fig 15: Identifying Heater To Register Duct No. 1 With Claws
      G05236223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE DEFROSTER NOZZLE ASSEMBLY 
    1. Release the 3 fitting claws and remove the defroster nozzle assembly.
      Fig 16: Identifying Defroster Nozzle Assembly With Claws
      G05236224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY 
    1. Disconnect the outer cable from the clamp.
    2. Disconnect the inner cable and defroster damper control cable sub-assembly.
      NOTE:
      • Be careful not to bend the cable wire.
      • If the cable wire bends, the air conditioning control assembly operationality becomes worse.
        Fig 17: Disconnecting Inner Cable And Defroster Damper Control Cable Sub-Assembly
        G05195334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT AIRMIX DAMPER CONTROL CABLE SUB-ASSEMBLY 
    1. Disconnect the outer cable from the clamp.
    2. Disconnect the inner cable and airmix damper control cable sub-assembly.
      NOTE:
      • Be careful not to bend the cable wire.
      • If the cable wire bends, the air conditioning control assembly operationality becomes worse.
        Fig 18: Disconnecting Inner Cable And Airmix Damper Control Cable Sub-Assembly
        G05195335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE ECM 
    1. Remove the 2 bolts and ECM.
      NOTE:
      • Do not apply excessive force to the connector of the ECM.
      • Do not give any impact to the ECM.
        Fig 19: Identifying ECM And Bolts
        G05195336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INSTRUMENT PANEL TO COWL BRACE CENTER 
    1. Remove the 2 nuts and instrument panel to cowl brace center.
      Fig 20: Identifying Instrument Panel To Cowl Brace Center
      G05236228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT STEERING COLUMN ASSEMBLY 
    1. Disconnect the connector and remove the 2 clamps.
      Fig 21: Identifying Connector And Clamps
      G05195338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and disconnect the steering column assembly.
  22. REMOVE INSTRUMENT PANEL REINFORCEMENT 
    1. Remove the 8 screws and 2 earth wires from the instrument panel reinforcement.
      Fig 22: Identifying Steering Column Assembly
      G05195339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 23: Identifying Earth Wires From Instrument Panel Reinforcement And Screw
      G05236231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 5 clamps and wire harness.
      Fig 24: Identifying Clamps And Wire Harness
      G05236232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and instrument panel reinforcement.
      Fig 25: Identifying Instrument Panel Reinforcement And Bolts
      G05236233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE AIR CONDITIONING UNIT ASSEMBLY 
    1. Release the 2 fitting claws and disconnect the connector holder.

      HINT:

      Release the claw while pressing the lock part in the direction of the arrow shown in illustration.

      Fig 26: Locating Connector Holder Lock Points
      G05195343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the blower w/fan motor sub-assembly.
      Fig 27: Locating Connector To Blower W/Fan Motor Sub-Assembly
      G05195344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector from the clamper servo sub-assembly.
      Fig 28: Locating Connector And Clamper Servo Sub-Assembly
      G05236236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector from the cooler thermistor No. 1.
      Fig 29: Locating Connector To Cooler Thermistor No. 1
      G05195346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 nuts, bolt and air conditioning unit assembly.
      Fig 30: Identifying Air Conditioning Unit Assembly
      G05195347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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