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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) >> Disassembly [10/2022 - ] >> Procedure

Disassembly [10/2022 - ]: Procedure

  1. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY 
    1. Remove the screw.
      GTY872606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      Front
    2. Disengage the 3 claws to remove the No. 3 air duct sub-assembly.
      NOTE:

      Be careful not to deform or damage the lower heater case of the air conditioner unit assembly when removing the No. 3 air duct sub-assembly.

  2. REMOVE ASPIRATOR 
    1. Disengage the guide and 2 claws to remove the aspirator.
      GTY918657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE BLOWER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  4. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Disconnect the connector.
      GTY896972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Remove the screw.
    3. Disengage the guide to remove the air conditioning amplifier assembly as shown in the illustration.
  5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY 
    1. Disconnect each connector.
      GTY1121984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage each clamp to remove the air conditioning harness assembly.
  6. REMOVE HEATER COVER 
    1. Remove the screw.
      GTY925963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Remove the heater cover as shown in the illustration.
  7. REMOVE DRAIN COOLER HOSE 
    1. Remove the drain cooler hose.
      GTY918611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY 
    1. GTY918584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.

  9. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY 
    1. GTY943917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 screws and No. 2 air conditioning radiator damper servo sub-assembly.

  10. REMOVE HEATER GROMMET 
    1. Remove the heater grommet.
      GTY918580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE HEATER CLAMP 
    1. GTY918579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 3 claws to remove the heater clamp.

  12. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY 
    1. GTY876634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction

      Remove the heater radiator unit sub-assembly as shown in the illustration.

      NOTE:

      Prepare a drain pan or cloth in case the coolant leaks.

  13. REMOVE COOLING UNIT PARTS 
    1. GTY918626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the cooling unit parts.

  14. REMOVE COOLER EXPANSION VALVE 
    1. GTY943927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using a 4 mm hexagon socket wrench, remove the 2 hexagon bolts and cooler expansion valve.

    2. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.
  15. REMOVE NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY 
    1. Remove the 2 screws.
      GTY918625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 10 claws to remove the upper heater case with No. 1 cooler evaporator sub-assembly from the lower heater case.
    3. Disengage the 2 clamps.
      GTY918623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the No. 1 cooler evaporator sub-assembly with No. 1 cooler thermistor from the upper heater case.
      NOTE:

      When the No. 1 cooler evaporator sub-assembly is removed, make sure to install a new one. The No. 1 cooler evaporator sub-assembly cannot be reused.

  16. REMOVE NO. 1 COOLER THERMISTOR 

    Refer to PROCEDURE - Step 10

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