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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (1 Of 3) >> FRONT AIR CONDITIONING UNIT (for HV Model) >> Removal [10/2022 - 11/2023] >> Procedure

Removal [10/2022 - 11/2023]: Procedure

  1. PRECAUTION 
    NOTE:

    Make sure to select face mode before disconnecting the cable from the negative (-) auxiliary battery terminal.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    See step  1

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  4. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 3

  5. REMOVE FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  6. REMOVE FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 5

  7. REMOVE FRONT FENDER SPLASH SHEILD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  8. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  9. REMOVE FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  10. REMOVE COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  11. DISCONNECT NO. 2 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the bolt and rotate the hook connector as shown in the illustration.
      GTY1113806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the No. 2 air conditioner tube and accessory assembly.
      GTY1113813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the No. 2 air conditioner tube and accessory assembly.
      NOTE:

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

  12. DISCONNECT OUTLET HEATER WATER HOSE B 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet heater water hose B.
      GTY916399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the outlet heater water hose B.
      • Prepare a drain pan or cloth in case the coolant leaks.
  13. DISCONNECT INLET HEATER WATER HOSE B 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose B.
      GTY916397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the inlet heater water hose B.
      • Prepare a drain pan or cloth in case the coolant leaks.
  14. REMOVE FRONT SEAT ASSEMBLY RH (for Manual Seat) 

    Refer to REMOVAL [10/2022 - 11/2023]

  15. REMOVE FRONT SEAT ASSEMBLY (for Power Seat) 

    Refer to REMOVAL [10/2022 - 11/2023]

  16. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to REMOVAL [10/2022 - 11/2023]

  17. REMOVE METER MIRROR SUB-ASSEMBLY (w/ Headup Display) 

    Refer to REMOVAL [10/2022 - 11/2023]

  18. REMOVE NO. 4 AIR DUCT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  19. REMOVE STEERING COLUMN ASSEMBLY 

    Refer to REMOVAL [10/2022 - 11/2023]

  20. REMOVE ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 7

  21. REMOVE PARKING ASSIST ECU WITH BRACKET 

    Refer to PROCEDURE - Step 3

  22. REMOVE NO. 1 CLEARANCE WARNING BUZZER 

    Refer to PROCEDURE - Step 24

  23. REMOVE COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Disconnect the connector and aspirator to remove the cooler (room temp. sensor) thermistor.
      GTY915642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 5

  25. REMOVE ACCELERATOR PEDAL 

    Refer to PROCEDURE - Step 6

  26. REMOVE REAR NO. 2 AIR DUCT 
    1. Disengage the 4 guides and turn back the front floor carpet assembly as shown in the illustration.
      GTY915640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip.
      GTY915638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 4 claws and remove the rear No. 2 air duct.
  27. REMOVE REAR NO. 1 AIR DUCT 
    1. Disengage the 4 claws and remove the rear No. 1 air duct.
      GTY915637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REAR NO. 4 AIR DUCT 
    1. Disengage the 4 guides and turn back the front floor carpet assembly as shown in the illustration.
      GTY943253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip.
      GTY943245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 4 claws and remove the rear No. 4 air duct.
  29. REMOVE REAR NO. 3 AIR DUCT 
    1. Disengage the 4 claws and remove the rear No. 3 air duct.
      GTY915604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 3 DASH PANEL INSULATOR PAD 
    1. Remove the No. 3 dash panel insulator pad.
      NOTE:

      If the No. 3 dash panel insulator pad is damaged, replace it with a new one.

      GTY915603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CENTER HEATER TO REGISTER SUB DUCT 
    1. Remove the 2 screws.
      GTY915602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to remove the center heater to register sub duct.
  32. DISCONNECT INSTRUMENT PANEL WIRE 
    1. Disconnect the connector.
      GTY984292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Earth Wire *b Connector Holder
      Bolt (A) Bolt (B)
      Connector Nut
    2. Remove the 4 bolts (A) and disconnect the 4 earth wires.
    3. Remove the 2 nuts.
    4. Remove the bolt (B) and disconnect the connector holder.
    5. Disengage each clamp.
    6. Disconnect the 2 connectors.
      GTY878925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Earth Wire
      Connector
      Bolt
    7. Disengage each clamp.
    8. Remove the bolt and disconnect the earth wire.
  33. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt, screw, nut and No. 1 instrument panel brace sub-assembly.
      GTY930488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  34. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Remove the bolt, screw, nut and No. 2 instrument panel brace sub-assembly.
      GTY864971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Nut
  35. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioner unit assembly when removing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
    • When disassembling the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. Remove the clip.
      GTY915599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the drain cooler hose.
      NOTE:

      If the drain cooler hose is disconnected from the cooler unit drain hose grommet, make sure to replace the cooler unit drain hose grommet with a new one. Failure to do so may lead to water ingress.

    3. Remove the cooler unit drain hose grommet.
      GTY915594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 hole plugs.
      GTY915592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 3 bolts.
      GTY943242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 4 bolts (A).
      GTY916720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A) Bolt (B)
      Nut - -
    7. Remove the bolt (B) and disconnect the brake pedal assembly.
    8. Remove the nut.
    9. Disengage each clamp.
      GTY921509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
    10. Disconnect the 4 connectors.
    11. Remove the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.
    12. Disengage the claw and 2 guides to disconnect the ID code box (immobiliser code ECU) as shown in the illustration.
      GTY841565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  36. REMOVE CENTER HEATER TO REGISTER DUCT 
    1. Disengage the 6 claws to remove the center heater to register duct.
      GTY915622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE AIR CONDITIONER UNIT ASSEMBLY 
    1. Remove the 3 bolts and the air conditioner unit assembly from the instrument panel reinforcement assembly.
      GTY915621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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