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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 Gasoline Model) >> Disassembly [10/2022 - 11/2023] >> Procedure

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

  1. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY 

    See step  1

  2. REMOVE GROMMET (for Manual Air Conditioning System) 
    1. Disengage the 2 claws to remove the grommet.
      GTY918654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ASPIRATOR (for Automatic Air Conditioning System) 

    See step  2

  4. REMOVE BLOWER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  5. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY 

    See step  4

  6. 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.
  7. REMOVE HEATER COVER (w/o PTC Heater) 

    See step  6

  8. REMOVE HEATER COVER (w/ PTC Heater) 
    1. Disengage the 2 clamps.
      GTY918600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 connectors to remove the No. 2 instrument panel wire.
      GTY918599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
      GTY943921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the claw and 2 guides to remove the heater cover.
  9. REMOVE QUICK HEATER ASSEMBLY (w/ PTC Heater) 
    1. Remove the quick heater assembly as shown in the illustration.
      GTY862646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  10. REMOVE DRAIN COOLER HOSE 

    See step  7

  11. REMOVE NO. 1 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY 
    1. for Single Type:
      1. Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.
        GTY918589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Dual Type:
      1. Remove the 3 screws and No. 1 air conditioning radiator damper servo sub-assembly.
        GTY918584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 AIR CONDITIONING RADIATOR DAMPER SERVO SUB-ASSEMBLY (for Automatic Air Conditioning System) 

    See step  9

  13. REMOVE HEATER GROMMET 

    See step  10

  14. REMOVE HEATER CLAMP 

    See step  11

  15. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY 

    See step  12

  16. REMOVE COOLING UNIT PARTS 

    See step  13

  17. REMOVE COOLER EXPANSION VALVE 

    See step  14

  18. 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. w/o Stop And Start System:
      1. Disengage the 2 clamps.
        GTY918623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. 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.

    4. w/ Stop And Start System:
      1. Disengage the 2 clamps.
        GTY918622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. 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.

  19. REMOVE NO. 1 COOLER THERMISTOR 

    Refer to PROCEDURE - Step 10

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