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Air Conditioning Unit: Removal

WARNING: This page is about a different car, the 2007 Lexus ES 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 
    1. Start up the engine.
    2. Turn the A/C switch on.
    3. Operate the cooler compressor at an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.
    4. Stop the engine.
    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.
  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. DISCONNECT BATTERY NEGATIVE TERMINAL 
    NOTE: Wait for 90 seconds after disconnecting the terminal to prevent the airbag from deploying (See AIRBAG SYSTEM ).
  4. REMOVE COOL AIR INTAKE DUCT SEAL  (See REMOVAL )
  5. REMOVE HOOD HINGE COVER (for LH Side)  (See REMOVAL )
  6. REMOVE HOOD HINGE COVER (for RH Side)  (See REMOVAL )
  7. REMOVE ENGINE ROOM SIDE COVER LH  (See REMOVAL )
  8. REMOVE ENGINE ROOM SIDE COVER RH  (See REMOVAL )
  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  10. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  11. REMOVE FRONT SUSPENSION UPPER CENTER BRACE  (See REMOVAL )
  12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  15. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  16. DISCONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the bolt, and slide the hook connector.
    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.
      Fig 1: Disconnecting Suction Pipe Sub-Assembly
      G05251186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY 
    1. Disconnect the air conditioner tube and accessory.
    2. Remove the O-ring from the air conditioner tube and accessory.
      NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
  18. 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.
      NOTE:
      • Do not apply excessive force to the heater outlet water hose.
      • Prepare a drain pan or cloth in case the coolant leaks.
    Fig 2: Identifying Heater Outlet Water Hose
    G05251187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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.

  20. REMOVE LOWER NO. 3 STEERING WHEEL COVER  (See REMOVAL )
  21. REMOVE LOWER NO. 2 STEERING WHEEL COVER  (See REMOVAL )
  22. REMOVE STEERING PAD  (See REMOVAL )
  23. REMOVE STEERING WHEEL ASSEMBLY  (See REMOVAL )
  24. REMOVE FRONT DOOR SCUFF PLATE LH  (See REMOVAL )
  25. REMOVE FRONT DOOR OPENING TRIM COVER LH  (See REMOVAL )
  26. REMOVE SIDE INSTRUMENT PANEL LH  (See REMOVAL )
  27. REMOVE INSTRUMENT PANEL FINISH PANEL END LH  (See REMOVAL )
  28. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See REMOVAL )
  29. REMOVE STEERING COLUMN COVER  (See REMOVAL )
  30. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  (See REMOVAL )
  31. REMOVE TILT & TELESCOPIC SWITCH  (See REMOVAL )
  32. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY  (See REMOVAL )
  33. REMOVE COMBINATION METER ASSEMBLY  (See REMOVAL )
  34. REMOVE NO. 1 SWITCH HOLE BASE  (See REMOVAL )
  35. REMOVE INSTRUMENT PANEL FINISH PANEL END RH  (See REMOVAL )
  36. REMOVE FRONT DOOR SCUFF PLATE RH  (See REMOVAL )
  37. REMOVE FRONT DOOR OPENING TRIM COVER RH  (See REMOVAL )
  38. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See REMOVAL )
  39. REMOVE SIDE INSTRUMENT PANEL RH  (See REMOVAL )
  40. REMOVE FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY  (See REMOVAL )
  41. REMOVE LOWER INSTRUMENT PANEL RH  (See REMOVAL )
  42. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY  (See REMOVAL )
  43. REMOVE UPPER CONSOLE PANEL ASSEMBLY WITH FRONT ASH RECEPTACLE  (See REMOVAL )
  44. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY  (See REMOVAL )
  45. REMOVE INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System)  (See REMOVAL )
  46. REMOVE MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System)  (See REMOVAL )
  47. REMOVE HEATER SEAT SWITCH CONSOLE BASE (w/o Seat Heater System)  (See REMOVAL )
  48. REMOVE HEATER SEAT SWITCH CONSOLE BASE (w/ Seat Heater System)  (See REMOVAL )
  49. REMOVE CONSOLE BOX POCKET  (See REMOVAL )
  50. REMOVE CONSOLE BOX CARPET  (See REMOVAL )
  51. REMOVE CONSOLE REAR END PANEL SUB-ASSEMBLY  (See REMOVAL )
  52. REMOVE REAR CONSOLE BOX ASSEMBLY  (See REMOVAL )
  53. REMOVE FRONT PILLAR GARNISH LH  (See REMOVAL )
  54. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See REMOVAL )
  55. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)  (See REMOVAL )
  56. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY  (See REMOVAL )
  57. REMOVE FRONT PILLAR GARNISH RH  (See REMOVAL )
  58. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See REMOVAL )
  59. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)  (See REMOVAL )
  60. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY  (See REMOVAL )
  61. REMOVE NO. 1 SPEAKER HOLE COVER  (See REMOVAL )
  62. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY  (See REMOVAL )
  63. REMOVE NO. 1 INSTRUMENT PANEL MOUNTING BRACKET  (See REMOVAL )
  64. REMOVE PUSH START SWITCH  (See REMOVAL )
  65. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY  (See REMOVAL )
  66. REMOVE ROOM TEMPERATURE SENSOR (See  REMOVAL   ) 
  67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (w/o DVD Player)  (See REMOVAL )
  68. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (w/ DVD Player)  (See REMOVAL )
  69. REMOVE FLOOR CARPET BRACKET LH 
    1. Release the 2 claws.
    2. Turn back the floor carpet.
      Fig 3: Releasing Claws
      G05251188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 clips.
    4. Remove the floor carpet bracket LH.
      Fig 4: Locating Floor Carpet Bracket Clips LH
      G05251189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE FLOOR CARPET BRACKET RH 
    1. Release the 2 claws.
    2. Turn back the floor carpet.
      Fig 5: Turning Back Floor Carpet Claws
      G05251190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 clips.
    4. Remove the floor carpet bracket RH.
      Fig 6: Locating Floor Carpet Bracket Clips RH
      G05251191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE NO. 2 CONSOLE BOX DUCT 
    1. Remove the bolt and No. 2 console box duct.
      Fig 7: Identifying No. 2 Console Box Duct And Bolts
      G05251192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE NO. 3 CONSOLE BOX DUCT 
    1. Remove the bolt and No. 3 console box duct.
      Fig 8: Identifying No. 3 Console Box Duct Bolt
      G05251193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE NO. 1 CONSOLE BOX DUCT 
    1. Remove the No. 1 console box duct.
      Fig 9: Identifying No. 1 Console Box Duct
      G05251194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE REAR NO. 2 AIR DUCT 
    1. Release the 2 claws and remove the rear No. 2 air duct.
      Fig 10: Identifying Rear No. 2 Air Duct Claws
      G05251195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE REAR NO. 1 AIR DUCT 
    1. Release the 2 claws and remove the rear No. 1 air duct.
    Fig 11: Identifying Rear No. 1 Air Duct Claws
    G05251196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY  (See REMOVAL )
  77. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY  (See REMOVAL )
  78. REMOVE STEERING COLUMN ASSEMBLY  (See DISASSEMBLY )
  79. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See  REMOVAL   ) 
  80. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Remove the 24 clamps, disconnect the 11 connectors, and then disconnect the wire harness.
    2. Remove the 8 nuts, 7 bolts, and junction block.
      Fig 12: Identifying Instrument Panel Reinforcement Assembly Clamps, Nuts And Bolts
      G05251197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the cap and bolt from the engine compartment side.
      Fig 13: Identifying Engine Compartment Side Cap And Bolt
      G05251198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 bolts and nut.
    5. Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts.
      Fig 14: Identifying Torx Bolts
      G05251199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The "TORX" bolts on the passenger side can be removed with the collars for adjustment.

    6. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly.
    7. Remove the 3 bolts, 2 screws, and instrument panel reinforcement assembly.
      Fig 15: Identifying Air Conditioner Unit Assembly Bolts And Screws
      G05251200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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