Toyota CH-R Service Manual: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the air conditioner unit assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Procedure	Necessary Procedures	Effects / Inoperative when not performed	Link
Disconnect cable from negative battery terminal	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)
		Pre-collision system
	Initialize back door lock	Power door lock control system
No. 1 Air Conditioning Radiator Damper Servo Sub-assembly No. 2 Air Conditioning Radiator Damper Servo Sub-assembly Air conditioning amplifier assembly	Initialize servo motor (Air conditioning system)	DTCs are stored

PROCEDURE

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (for HFC-134a(R134a))

Click here

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (for HFO-1234yf(R1234yf))

Click here

3. DRAIN ENGINE COOLANT

Click here

4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

5. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click here

6. REMOVE WATER GUARD PLATE LH

Click here

7. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

Click here

8. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

Click here

9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

10. DISCONNECT OUTLET HEATER WATER HOSE

(a) Slide the hose clip to disconnect the outlet heater water hose. NOTICE: To prevent contamination by foreign matter or water droplets, protect the connecting portions of the outlet heater water hose and air conditioner radiator assembly with plastic bags. Do not apply excessive force to the outlet heater water hose. Prepare a drain pan or cloth in case the coolant leaks.

11. DISCONNECT INLET HEATER WATER HOSE

(a) Slide the hose clip to disconnect the inlet heater water hose. NOTICE: To prevent contamination by foreign matter or water droplets, protect the connecting portions of the inlet heater water hose and air conditioner radiator assembly with plastic bags. Do not apply excessive force to the inlet heater water hose. Prepare a drain pan or cloth in case the coolant leaks.

12. DISCONNECT SUCTION PIPE SUB-ASSEMBLY

(a) Remove the bolt.

(b) Disconnect the suction pipe sub-assembly and cooler refrigerant liquid pipe A shown in the illustration.

(c) Remove the 2 O-rings from the suction pipe sub-assembly and cooler refrigerant liquid pipe A.

NOTICE:

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

13. REMOVE FRONT SEAT ASSEMBLY LH

Click here

14. REMOVE FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

15. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

16. REMOVE STEERING COLUMN ASSEMBLY

Click here

17. REMOVE WINDSHIELD WIPER RELAY ASSEMBLY

Click here

18. REMOVE ECU INTEGRATION BOX RH

Click here

19. REMOVE COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)

(a) Disconnect the connector and aspirator to remove the cooler thermistor (room temperature sensor).

20. REMOVE NO. 3 DASH PANEL INSULATOR PAD

(a) Disengage the clips to remove the No. 3 dash panel insulator pad.

(b) Remove the 2 front floor carpet clips.

(c) Remove the clip.

Remove in this Direction

(d) Disengage the clamps to turn back the front floor carpet assembly as shown in the illustration.

21. REMOVE REAR NO. 6 AIR DUCT (w/ Rear Air Duct)

(a) Disengage the claws to remove the rear No. 6 air duct as shown in the illustration.

Remove in this Direction

22. REMOVE REAR NO. 5 AIR DUCT (w/ Rear Air Duct)

Remove in this Direction

(a) Disengage the claws to remove the rear No. 5 air duct as shown in the illustration.

23. REMOVE REAR NO. 4 AIR DUCT (w/ Rear Air Duct)

(a) Remove the 2 front floor carpet clips.

(b) Remove the clip.

Remove in this Direction

(c) Disengage the clamps to turn back the front floor carpet assembly as shown in the illustration.

(d) Disengage the claws to remove the rear No. 4 air duct as shown in the illustration.

Remove in this Direction

24. REMOVE REAR NO. 3 AIR DUCT (w/ Rear Air Duct)

(a) Disengage the claws to remove the rear No. 3 air duct as shown in the illustration.

Remove in this Direction

25. REMOVE REAR NO. 2 AIR DUCT (w/ Rear Air Duct)

Remove in this Direction

(a) Disengage the claws to remove the rear No. 2 air duct.

26. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct)

(a) Disengage the claws to remove the rear No. 1 air duct as shown in the illustration.

Remove in this Direction

27. DISCONNECT NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) w/ PTC Heater:

(1) Remove the bolt to disconnect the ground wire.

(b) Remove the 2 nuts and separate the relay block assembly.

(c) Disengage the clamps to disconnect the wire harness.

(d) Remove the bolt, screw, nut and No.1 instrument panel brace sub-assembly.

28. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Remove the bolt to disconnect the ground wire.

(b) Disengage the clamps to disconnect the wire harness.

(c) Remove the bolt, screw, nut and No. 2 instrument panel brace sub-assembly.

29. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY (for Cold Area Specification Vehicles)

(a) Disengage the clamp and claws.

(b) Remove the bolt, nut and No. 3 instrument panel to cowl brace sub-assembly.

30. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY (except Cold Area Specification Vehicles)

(a) Disengage the clamp and claws.

(b) Remove the bolt, nut and No. 3 instrument panel to cowl brace sub-assembly.

31. SEPARATE DRAIN COOLER HOSE

(a) Disconnect the drain cooler hose. NOTICE: If the cooler unit drain hose grommet is disconnected from the vehicle body while disconnecting the drain cooler hose, make sure to replace it with a new one. Failure to do so may cause water ingress.

*1 Cooler Unit Drain Hose Grommet

32. DISCONNECT INSTRUMENT PANEL WIRE

(a) Disconnect each connector.

*a

Clamp

*b

Hook

(b) Remove the bolt and screw.

(c) Remove the 4 bolts to disconnect the 4 ground wires.

(d) Remove the bolt and nut to separate the instrument panel junction block assembly with main body ECU.

(e) Disengage clamps and hook to disconnect the instrument panel wire.

33. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

(a) Remove the 2 bolts.

(b) Remove the 5 bolts.

(c) Remove the nut.

(d) Disengage the clamps.

(e) Disconnect 2 connectors.

(f) Disengage the guides to remove the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

Remove in this Direction

-

-

34. REMOVE AIR CONDITIONER UNIT ASSEMBLY

(a) Remove the 3 bolts and air conditioner unit assembly from the instrument panel reinforcement assembly.

35. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Disengage the claws to remove the lower defroster nozzle assembly.