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Air Conditioning Unit: Removal: Removal

WARNING: This page is about a different car, the 2011 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. PRECAUTION 

    Refer to PRECAUTION

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  See step  1
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    WARNING:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. Refer to PRECAUTION .

    HINT: 

    Before disconnecting the cable, set the air conditioning control switch to DEF-MODE. (for Automatic Air Conditioning System)

  5. REMOVE FRONT WIPER ARM HEAD CAP  . Refer to REMOVAL - Step 1
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to REMOVAL - Step 2
  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to REMOVAL - Step 3
  8. REMOVE HOOD TO COWL TOP SEAL  . Refer to REMOVAL - Step 4
  9. REMOVE CENTER NO. 1 COWL TOP VENTILATOR LOUVER  . Refer to REMOVAL - Step 5
  10. REMOVE COWL TOP VENTILATOR LOUVER LH  . Refer to REMOVAL - Step 6
  11. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to REMOVAL - Step 7
  12. REMOVE OUTER COWL TOP PANEL (for TMC Made)  . Refer to REMOVAL - Step 14
  13. REMOVE OUTER COWL TOP PANEL (except TMC Made)  . Refer to REMOVAL - Step 15
  14. DISCONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the bolt and slide the hook connector.
      Fig 1: Identifying Suction Pipe Sub-Assembly
      GTY208561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the suction pipe sub-assembly.
    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.

  15. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY 
    1. Disconnect the air conditioning tube assembly.
    2. Remove the O-ring from the air conditioning tube assembly.
      NOTE:

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

  16. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.
      Fig 2: Locating Heater Inlet Water Hose
      GTY208563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the heater outlet water hose.
      • Prepare a drain pan or a piece of cloth in case the coolant leaks.
  17. DISCONNECT HEATER INLET WATER HOSE 

    HINT: 

    Disconnection procedure for the heater inlet water hose is the same as that for the heater outlet water hose.

  18. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH  . Refer to REMOVAL - Step 3
  19. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL RH  . Refer to REMOVAL - Step 4
  20. REMOVE INSTRUMENT PANEL FINISH PANEL END LH  . Refer to REMOVAL - Step 5
  21. REMOVE INSTRUMENT PANEL FINISH PANEL END RH  . Refer to REMOVAL - Step 6
  22. REMOVE CENTER INSTRUMENT PANEL REGISTER ASSEMBLY  . Refer to REMOVAL - Step 7
  23. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY  . Refer to REMOVAL - Step 3
  24. REMOVE COMBINATION METER ASSEMBLY  . Refer to REMOVAL - Step 4
  25. REMOVE FRONT PILLAR GARNISH LH  . Refer to REMOVAL - Step 36
  26. REMOVE FRONT PILLAR GARNISH RH  . Refer to REMOVAL - Step 37
  27. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY  . Refer to REMOVAL - Step 12
  28. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH  . Refer to REMOVAL - Step 41
  29. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  . Refer to REMOVAL - Step 14
  30. REMOVE NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY  . Refer to REMOVAL - Step 15
  31. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH  . Refer to REMOVAL - Step 46
  32. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY  . Refer to REMOVAL - Step 17
  33. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 18
  34. REMOVE POWER STEERING ECU ASSEMBLY (for 2ZR-FE)  . Refer to REMOVAL - Step 4
  35. REMOVE POWER STEERING ECU ASSEMBLY (for 2AZ-FE)  . Refer to REMOVAL - Step 4
  36. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 32
  37. REMOVE STEERING WHEEL ASSEMBLY (w/o Front Spoiler) 

    Refer to REMOVAL

  38. REMOVE STEERING WHEEL ASSEMBLY (w/ Front Spoiler) 

    Refer to REMOVAL

  39. REMOVE LOWER STEERING COLUMN COVER  . Refer to REMOVAL - Step 6
  40. REMOVE UPPER STEERING COLUMN COVER  . Refer to REMOVAL - Step 7
  41. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  . Refer to REMOVAL - Step 8
  42. REMOVE COLUMN HOLE COVER SILENCER SHEET  . Refer to REMOVAL - Step 10
  43. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  . Refer to REMOVAL - Step 11
  44. REMOVE INSTRUMENT PANEL SUB REINFORCEMENT  . Refer to REMOVAL - Step 12
  45. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY  . Refer to REMOVAL - Step 13
  46. REMOVE TRANSPONDER KEY AMPLIFIER (w/o Smart Key System)  . Refer to REMOVAL - Step 14
  47. REMOVE STOP LIGHT SWITCH ASSEMBLY  . Refer to REMOVAL - Step 1
  48. REMOVE STEERING POST ASSEMBLY (for 2ZR-FE)  . Refer to REMOVAL - Step 16
  49. REMOVE STEERING POST ASSEMBLY (for 2AZ-FE)  . Refer to REMOVAL - Step 17
  50. REMOVE RADIO RECEIVER WITH BRACKET (w/o Navigation System)  . Refer to REMOVAL - Step 6
  51. REMOVE NAVIGATION RECEIVER WITH BRACKET (w/ Navigation System)  . Refer to REMOVAL - Step 7
  52. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  . Refer to REMOVAL - Step 21
  53. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle)  . Refer to REMOVAL - Step 22
  54. REMOVE CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle)  . Refer to REMOVAL - Step 23
  55. REMOVE CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle)  . Refer to REMOVAL - Step 24
  56. REMOVE INSTRUMENT PANEL BOX ASSEMBLY  . Refer to REMOVAL - Step 25
  57. REMOVE INSTRUMENT PANEL HOLE COVER  . Refer to REMOVAL - Step 26
  58. REMOVE AIR CONDITIONING PANEL ASSEMBLY (for Manual Air Conditioning System)  . Refer to REMOVAL - Step 14
  59. REMOVE AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System)  . Refer to REMOVAL - Step 14
  60. REMOVE FRONT DOOR SCUFF PLATE LH  . Refer to REMOVAL - Step 39
  61. REMOVE COWL SIDE TRIM BOARD LH  . Refer to REMOVAL - Step 40
  62. REMOVE FRONT NO. 1 CONSOLE BOX INSERT  . Refer to REMOVAL - Step 31
  63. REMOVE NO. 1 SWITCH HOLE BASE (w/o Smart Key System)  . Refer to REMOVAL - Step 33
  64. REMOVE NO. 1 SWITCH HOLE BASE (w/ Smart Key System)  . Refer to REMOVAL - Step 34
  65. REMOVE FRONT DOOR SCUFF PLATE RH  . Refer to REMOVAL - Step 44
  66. REMOVE COWL SIDE TRIM BOARD RH  . Refer to REMOVAL - Step 45
  67. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover)  . Refer to REMOVAL - Step 37
  68. REMOVE FRONT NO. 2 CONSOLE BOX INSERT  . Refer to REMOVAL - Step 38
  69. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 10
  70. REMOVE CONSOLE BOX CARPET  . Refer to REMOVAL - Step 12
  71. REMOVE CONSOLE BOX ASSEMBLY (for Manual Transaxle)  . Refer to REMOVAL - Step 13
  72. REMOVE CONSOLE BOX ASSEMBLY (for Automatic Transaxle)  . Refer to REMOVAL - Step 14
  73. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY  . Refer to REMOVAL - Step 4
  74. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 44
  75. REMOVE SMART KEY ECU ASSEMBLY (w/ Smart Key System)  . Refer to REMOVAL - Step 2
  76. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY 
    1. Remove the 2 nuts and the No. 1 air duct sub-assembly.
      Fig 3: Locating No 1 Air Duct Sub-Assembly Nuts
      GTY208564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Disengage the 6 claws and remove the lower defroster nozzle assembly.
      Fig 4: Identifying Lower Defroster Nozzle Assembly And Claws
      GTY208565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE CENTER INSTRUMENT PANEL TO COWL BRACE 
    1. Remove the 2 bolts and the center instrument panel to cowl brace.
      Fig 5: Locating Center Instrument Panel To Cowl Brace And Bolts
      GTY207423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE REAR NO. 2 AIR DUCT (w/ Rear Air Duct) 
    1. Remove the clip.
      Fig 6: Turning Back Floor Carpet
      GTY207421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the floor carpet.
    3. Disengage the 2 claws and remove the rear No. 2 air duct.
      Fig 7: Identifying Rear No. 2 Air Duct And Claws
      GTY207422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE REAR NO. 3 AIR DUCT (w/ Rear Air Duct) 
    1. Remove the clip.
      Fig 8: Turning Back Floor Carpet
      GTY207420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn back the floor carpet.
    3. Disengage the 2 claws and remove the rear No. 3 air duct.
      Fig 9: Identifying Rear No. 3 Air Duct And Claws
      GTY185416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Manual Air Conditioning System) 
    1. for TMC made:
      1. Disconnect the connector.
        Fig 10: Locating No 1 Instrument Panel Brace Sub-Assembly And Connector (TMC Made)
        GTY208610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage each clamp.
    2. except TMC made:
      1. Disconnect the connector.
        Fig 11: Locating No 1 Instrument Panel Brace Sub-Assembly And Connector (TMC And NUMMI Made)
        GTY208566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage each clamp.
    3. Remove the screw.
      Fig 12: Identifying No 1 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      GTY208482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt, the nut, and the No. 1 instrument panel brace sub-assembly.
  82. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Automatic Air Conditioning System) 
    1. for TMC Made:
      1. Disengage each clamp.
        Fig 13: Identifying No 1 Instrument Panel Brace Sub-Assembly And Clamp
        GTY183155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. except TMC made:
      1. Disengage each clamp.
        Fig 14: Identifying No 1 Instrument Panel Brace Sub-Assembly And Clamp
        GTY179865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
      Fig 15: Identifying No 1 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      GTY208482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt, the nut, and the No. 1 instrument panel brace sub-assembly.
  83. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. for TMC Made:
      1. Disengage each clamp.
        Fig 16: Identifying No 2 Instrument Panel Brace Sub-Assembly And Clamp
        GTY208567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. except TMC made:
      1. Disengage each clamp.
        Fig 17: Identifying No 2 Instrument Panel Brace Sub-Assembly And Clamp
        GTY182999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
      Fig 18: Identifying No 2 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      GTY207424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt, the nut, and the No. 2 instrument panel brace sub-assembly.
  84. REMOVE HEATER COVER (w/ Cover) 
    1. Disengage the 4 claws and remove the heater cover.
      Fig 19: Identifying Heater Cover And Claws
      GTY207426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct) 
    1. Disengage the 4 claws and remove the rear No. 1 air duct.
      Fig 20: Identifying Rear No 1 Air Duct And Claws
      GTY207427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Manual Air Conditioning System) 
    1. Disconnect the connector.
    2. Disengage each clamp and the wire harness.
      Fig 21: Identifying Wire Harness And Clamp
      GTY208568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect each connector.
    4. Disengage each clamp.
    5. Remove the 12 bolts, and disengage the wire harness and junction block.
    6. Disengage the cooler drain hose.
      Fig 22: Locating Wire Harness And Junction Block With Bolts
      GTY190921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 7 bolts.
      Fig 23: Identifying Instrument Panel Reinforcement Assembly With Bolts
      GTY174101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 3 bolts and the instrument panel reinforcement assembly.
      Fig 24: Locating Instrument Panel Reinforcement Assembly And Bolts
      GTY208569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Automatic Air Conditioning System) 
    1. Disengage each clamp and the wire harness.
      Fig 25: Identifying Wire Harness And Clamp
      GTY178434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector.
    3. Disengage each clamp.
    4. Remove the 12 bolts, and disengage the wire harness and junction block.
    5. Disengage the cooler drain hose.
      Fig 26: Locating Wire Harness And Junction Block And Bolts
      GTY185220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 7 bolts.
      Fig 27: Identifying Instrument Panel Reinforcement Assembly With Bolts
      GTY174101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and the instrument panel reinforcement assembly.
      Fig 28: Locating Instrument Panel Reinforcement Assembly And Bolts
      GTY208569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE AIR CONDITIONING UNIT 
    1. Remove the bolt, the nut, and the air conditioning unit.
      Fig 29: Locating Air Conditioning Unit With Bolt And Nut
      GTY207478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
      • When disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
  89. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY 
    1. Disengage the 2 claws and remove the No. 2 air duct sub-assembly.
      Fig 30: Identifying No 2 Air Duct Sub-Assembly And Claws
      GTY207479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE BLOWER ASSEMBLY (w/o PTC Heater) 
    1. for Automatic Air Conditioning System:
      1. Disconnect the connector.
        Fig 31: Locating Blower Assembly And Screws
        GTY207480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws and the blower assembly.
  91. REMOVE BLOWER ASSEMBLY (w/ PTC Heater) 
    1. Disengage each clamp.
      Fig 32: Identifying Blower Assembly And Clamp
      GTY183080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw and disengage the quick heater connector.
      Fig 33: Locating Blower Assembly And Screws
      GTY167404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. for Automatic Air Conditioning System:
      1. Disconnect the connector.
    4. Remove the 3 screws and the blower assembly.
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