Removal

AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL

1. PRECAUTION

Service Precautions

2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Wait at least for 90 seconds after disconnecting the cable to prevent the airbag from working.

4. DRAIN ENGINE COOLANT (for 2TR-FE) Service and Repair

5. DRAIN ENGINE COOLANT (for 1GR-FE) Service and Repair

6. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the 2 bolts and separate the suction hose sub-assembly.

(b) Insert 2 screwdrivers into the 2 piping clamp slots, and while holding them down, disengage the piping clamp claws and the piping clamp.

NOTICE:
* Do not use a screwdriver or any other tool to disconnect the hose.
* Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

(d) Remove the 2 O-rings from the suction hose sub-assembly.

7. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY

(a) Remove the bolt.

(b) Disengage the 2 clamps and separate the air conditioning tube assembly.

(c) Insert 2 screwdrivers into the 2 piping clamp slots, and while holding them down, disengage the piping clamp claws and the piping clamp.

(d) Disconnect the air conditioner tube.

NOTICE:
* Do not use a screwdriver or any other tool to disconnect the tube.
* Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

(e) Remove the 2 O-rings from the air conditioner tube.

8. DISCONNECT HEATER WATER INLET HOSE (for 2TR-FE)

(a) Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water inlet hose from the heater unit.

9. DISCONNECT HEATER WATER INLET HOSE (for 1GR-FE)

(a) Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water inlet hose from the heater unit.

10. DISCONNECT HEATER WATER OUTLET HOSE (for 2TR-FE)

(a) Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water outlet hose from the heater unit.

11. DISCONNECT HEATER WATER OUTLET HOSE (for 1GR-FE)

(a) Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water outlet hose from the heater unit.

12. REMOVE FRONT WIPER ARM HEAD CAP Removal

13. REMOVE FRONT WIPER ARM LH Removal

14. REMOVE FRONT WIPER ARM RH Removal

15. REMOVE FRONT FENDER TO COWL SIDE SEAL LH Removal

16. REMOVE FRONT FENDER TO COWL SIDE SEAL RH Removal

17. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

18. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

19. REMOVE LOWER NO. 2 STEERING WHEEL COVER Removal

20. REMOVE LOWER NO. 3 STEERING WHEEL COVER Removal

21. REMOVE HORN BUTTON ASSEMBLY Removal

22. REMOVE STEERING WHEEL ASSEMBLY Removal

23. REMOVE STEERING COLUMN COVER LOWER Removal

24. REMOVE STEERING COLUMN COVER UPPER Removal

25. REMOVE SPIRAL CABLE SUB-ASSEMBLY Removal

26. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY Removal

27. REMOVE FRONT FLOOR FOOTREST Removal

28. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) Removal

29. REMOVE FRONT DOOR SCUFF PLATE LH (for Access Cab) Removal

30. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) Removal

31. REMOVE FRONT DOOR SCUFF PLATE RH (for Regular Cab) Removal

32. REMOVE FRONT DOOR SCUFF PLATE RH (for Access Cab) Removal

33. REMOVE FRONT DOOR SCUFF PLATE RH (for Double Cab) Removal

34. REMOVE COWL SIDE TRIM BOARD LH (for Regular Cab) Removal

35. REMOVE COWL SIDE TRIM BOARD LH (for Access Cab) Removal

36. REMOVE COWL SIDE TRIM BOARD LH (for Double Cab) Removal

37. REMOVE COWL SIDE TRIM BOARD RH (for Regular Cab) Removal

38. REMOVE COWL SIDE TRIM BOARD RH (for Access Cab) Removal

39. REMOVE COWL SIDE TRIM BOARD RH (for Double Cab) Removal

40. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP LH

(a) Separate the front door opening trim weatherstrip LH.

41. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

(a) Separate the front door opening trim weatherstrip RH.

42. REMOVE FRONT PILLAR GARNISH LH (for Regular Cab) Removal

43. REMOVE FRONT PILLAR GARNISH LH (for Access Cab) Removal

44. REMOVE FRONT PILLAR GARNISH LH (for Double Cab) Removal

45. REMOVE FRONT PILLAR GARNISH RH (for Regular Cab) Removal

46. REMOVE FRONT PILLAR GARNISH RH (for Access Cab) Removal

47. REMOVE FRONT PILLAR GARNISH RH (for Double Cab) Removal

48. REMOVE INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake) Removal

49. REMOVE INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake) Removal

50. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Automatic Transmission on Separate Seat Type) Removal

51. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Manual Transmission on Separate Seat Type) Removal

52. REMOVE REAR CONSOLE BOX ASSEMBLY (for Separate Seat Type) Removal

53. REMOVE INSTRUMENT PANEL CUP HOLDER TRAY (for Automatic Transmission on Separate Seat Type) Removal

54. REMOVE FRONT CONSOLE BOX (for Automatic Transmission on Separate Seat Type) Removal

55. REMOVE FRONT CONSOLE BOX (for Manual Transmission on Separate Seat Type) Removal

56. REMOVE FRONT CONSOLE BOX (for Automatic Transmission on Bench Seat Type) Removal

57. REMOVE FRONT CONSOLE BOX (for Manual Transmission on Bench Seat Type) Removal

58. REMOVE AIR CONDITIONING CONTROL ASSEMBLY Removal

59. REMOVE RADIO RECEIVER ASSEMBLY Removal

60. SEPARATE HOOD LOCK CONTROL LEVER SUB-ASSEMBLY Disassembly

61. REMOVE LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL Removal

62. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Removal

63. REMOVE COMBINATION METER ASSEMBLY Removal

64. REMOVE INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY Removal

65. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY Removal

66. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH Removal

67. REMOVE LOWER INSTRUMENT PANEL LH Removal

68. REMOVE INSTRUMENT LOWER COVER SUB-ASSEMBLY Removal

69. REMOVE INSTRUMENT SIDE PANEL RH Removal

70. DISCONNECT PASSENGER AIRBAG CONNECTOR Removal

71. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY W/ PASSENGER AIRBAG ASSEMBLY Removal

72. REMOVE NO. 1 HEATER TO REGISTER DUCT

(a) Remove the nut and heater to register duct.

73. REMOVE NO. 3 HEATER TO REGISTER DUCT

(a) Remove the nut and heater to register duct.

74. REMOVE NO. 2 REAR AIR DUCT (for Double Cab)

(a) Fold back the floor carpet.

(b) Disengage the 2 claws and remove the air duct rear.

75. REMOVE NO. 1 REAR AIR DUCT (for Double Cab)

(a) Fold back the floor carpet.

(b) Disengage the 2 claws and remove the air duct rear.

76. REMOVE AIR DUCT ASSEMBLY LH

(a) Remove the clip.

(b) Disengage the 4 claws and remove the air duct assembly heater.

77. REMOVE AIR DUCT ASSEMBLY RH

(a) Disengage the 3 claws and remove the air duct assembly.

78. REMOVE NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET

(a) Remove the bolt, nut and instrument panel brace mounting bracket LH.

(b) Remove the bolt, nut and instrument panel brace mounting bracket RH.

79. REMOVE STEERING COLUMN HOLE COVER Removal

80. SEPARATE STEERING SLIDING YOKE Removal

81. REMOVE STEERING COLUMN ASSEMBLY Removal

82. REMOVE PARKING BRAKE CONTROL LEVER ASSEMBLY (for Lever Type Parking Brake) Removal

83. REMOVE ECM (for 2TR-FE) Removal

84. REMOVE ECM (for 1GR-FE) Removal

85. SEPARATE DRIVER SIDE JUNCTION BLOCK

(a) Remove the 2 bolts and bracket.

(b) Remove the 2 nuts and separate the driver side junction block assembly.

86. REMOVE TRANSPONDER KEY ECU ASSEMBLY

(a) Disconnect the connector.

(b) Remove the nut and the transponder key ECU assembly.

87. REMOVE AIR CONDITIONER AMPLIFIER ASSEMBLY

(a) Disconnect the connector.

(b) Remove the nut and the air conditioner amplifier assembly.

88. REMOVE AIR CONDITIONING UNIT ASSEMBLY

(a) Disengage the 4 clamps and disconnect the 6 connectors from the air conditioning unit assembly.

(b) Remove the 3 bolts.

(c) Disconnect the connector.

(d) Disconnect the 2 airbag connectors Service Precautions.

(e) Disengage the 20 clamps.

(f) Remove the 5 bolts and 2 nuts.

(g) Remove the 2 caps and 7 bolts.

(h) Disengage the reinforcement hook of the air conditioning unit, and remove the reinforcement.

(i) Remove the air conditioner unit assembly.