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 and installed, or replaced during air conditioning unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Procedure

Necessary Procedure

Effect/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
  • Air conditioning amplifier assembly

Initialize servo motor (Air conditioning system)

DTCs are stored

PROCEDURE

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

2. DRAIN ENGINE COOLANT

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

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

Click here

5. REMOVE WATER GUARD PLATE LH

Click here

6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

Click here

7. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

Click here

8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

9. 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.

10. 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.

11. DISCONNECT SUCTION PIPE SUB-ASSEMBLY

(a) Remove the bolt and rotate the hook connector as shown in the illustration.

Remove in this Direction

(b) Disconnect the suction pipe sub-assembly.

(c) Remove the 2 O-ring from the suction pipe subassembly.

NOTICE:

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

12. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A

(a) Remove the bolt and the cooler refrigerant liquid pipe A.

(b) Remove the O-ring from the 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. INSTALL 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) 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 clips to remove the No. 3 dash panel insulator pad.

21. REMOVE REAR NO. 6 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

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

(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

(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

Remove in this Direction

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

26. REMOVE REAR NO. 1 AIR DUCT

(a) Disengage the claws to remove the rear No. 1 air duct.

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

(a) 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 the 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 the No. 2 instrument panel brace sub-assembly.

29. REMOVE NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

(a) Disengage the clamp and claws.

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

30. 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.

31. DISCONNECT 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. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:

  • 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.

(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

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33. REMOVE AIR CONDITIONER UNIT ASSEMBLY

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

34. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Disengage the 6 claws to remove the lower defroster nozzle assembly.

    Disassembly
    DISASSEMBLY PROCEDURE 1. PRECAUTION NOTICE: Make sure to perform initialization after replacing the air conditioning radiator damper servo sub-assembly. If initialization is not performed, the a ...

    Reassembly
    REASSEMBLY PROCEDURE 1. INSTALL NO. 1 COOLER THERMISTOR Click here 2. INSTALL NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY (a) Install the No. 1 cooler evaporator sub-assembly with the No. ...

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