Automatic A/c-Heater Systems: Removal & Installation Toyota Prius I рестайлинг

REMOVAL & INSTALLATION

1. Run engine at idle with A/C on for about 10 minutes. Stop engine. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove drive belt. Remove engine undercover.
2. Remove 2 discharge and suction hose bolts. Disconnect discharge and suction hoses. Cap openings. Remove 4 compressor bolts. Remove compressor. To install, reverse removal procedure.

Pull off 5 control knobs. Remove 3 nuts. Remove 4 multi display and radio screws. Remove multi display and radio. Remove 12 A/C control assembly screws. Remove A/C control assembly and cover. Disconnect connector lock and pull out flat harness from center cluster panel. Using screwdriver, turn bulb to left and remove bulb. Remove 6 cluster module screws. Remove center cluster panel. (Scheme 7) To install, reverse removal procedure.

Scheme 7

Scheme 8

1. Disconnect negative battery cable. Remove front wiper and outer front cowl top panel. Drain engine coolant. Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Using A/C Line Coupling Tool (09870-00015) and A/C Line Coupling Tool (09870-00025) disconnect liquid and suction lines at engine compartment side of cowl. Seal openings. Disconnect heater hoses. Remove instrument panel and reinforcement. See «INSTRUMENT PANEL»(ref-98934-S11331215272001070200000). Remove blower unit. See «BLOWER UNIT»(ref-98934-S37781492602001072300000).
3. Remove 2 defroster duct screws. Remove foot air duct. Disconnect electrical connectors. Remove 2 A/C-heater unit nuts. Remove A/C-heater unit. (Scheme 8) To install, reverse removal procedure.

Remove air/pollen filter. See AIR/POLLEN FILTER. Remove blower motor control. Remove blower motor. See BLOWER UNIT. Remove 3 air inlet control servomotor screws. Remove air inlet control servomotor. (Scheme 9) To install, reverse removal procedure.

Scheme 9

Remove instrument panel and reinforcement. See INSTRUMENT PANEL. Remove 3 air mix servomotor screws. (Scheme 10) Remove air mix servomotor. To install, reverse removal procedure.

Scheme 10

Remove instrument panel and reinforcement. See INSTRUMENT PANEL. Remove 4 air outlet servomotor screws. (Scheme 11) Remove air outlet servomotor. To install, reverse removal procedure.

Scheme 11

Remove 2 pins in glove box. Open glove box widely by pulling it down. Pull out filter case. Remove air/pollen filter. (Scheme 12) To install, reverse removal procedure.

Remove glove box door. Disconnect electrical connector. Using a knife, cut off glove box reinforcement. Remove 2 ECM and EMPS ECU bolts. Remove ECM and EMPS ECUs. Remove 2 blower unit screws and nuts. Remove blower unit. (Scheme 12) To install, reverse removal procedure.

Scheme 12

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain engine coolant. Remove condenser fan. Remove front bumper. Remove radiator reservoir hose. Remove 2 discharge and liquid tube bolts. Disconnect discharge and liquid lines. Seal openings. Remove 2 bolts and 2 radiator upper supports.
2. Push radiator and condenser unit toward engine, and pull upward. Pull down on lower radiator support to remove. Remove lower radiator support. Remove radiator and condenser unit. To install, reverse removal procedure.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove blower unit. See BLOWER UNIT. Pry out packing. Remove 2 expansion valve bolts. Remove expansion valve. (Scheme 13) Cap fittings. To install, reverse removal procedure.

Scheme 13

1. Remove A/C-heater unit. See «A/C-HEATER UNIT»(ref-98934-S23818315032001072300000) . Remove foot air ducts, thermistor, expansion valve, PTC heater, drain hose, and aspirator and hose. See «THERMISTOR»(ref-98934-S28669383892001070200000) , «EXPANSION VALVE»(ref-98934-S06128807632001072700000) and «PTC HEATER»(ref-98934-S00780034692001072300000) .
2. Remove heater pipe cover and heater core. See «HEATER CORE»(ref-98934-S10581858472001070200000) . Remove evaporator. To install, reverse removal procedure.

Remove A/C-heater unit. See A/C-HEATER UNIT. Remove foot air ducts. Remove thermistor. Remove expansion valve. Remove PTC heater. See PTC HEATER. Remove foot air duct. Disconnect PTC heater connector. Remove 2 screws and rear foot duct. Remove heater core screws. Remove heater core. (Scheme 8) To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove steering wheel pad and steering wheel. See AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Remove front door scuff plates. Remove kick panels. Remove front pillar molding.
2. Remove 2 hood release lever screws. Remove hood release lever. Zip open shift hole cover. Remove bolt and screw. Remove lower finish panel. Disconnect electrical connectors and data link connector. Remove shifting hole cover from lower finish panel. Remove finish panel.
3. Remove upper and lower steering column covers. Remove spiral cable (clockspring). See AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Remove glove box door.
4. Remove 2 lower center cluster finish panel clips. Use a taped screwdriver, remove lower center cluster finish panel. Remove glove compartment door reinforcement (if equipped). Disconnect passenger-side air bag connector. Disengage air bag connector clamp from center clamp. Remove passenger air bag assembly. See AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT.
5. Pry out hazard warning switch. Disconnect electrical connector. Remove 2 cluster finish panel screws. Remove cluster finish panel. Remove radio. Pry off instrument cluster trim. Remove 3 instrument cluster screws. Remove instrument cluster. Pry out left and right defroster nozzles. Using a taped screwdriver, unclip air outlet registers from both sides of instrument panel.
6. Remove steering column. See appropriate STEERING COLUMNS article. Disconnect electrical connectors. Remove 4 bolts, 3 screws and instrument panel. Remove brace. Remove 2 bolts, 4 nuts and instrument panel reinforcement. To install, reverse removal procedure.

Remove instrument panel and reinforcement. See INSTRUMENT PANEL. Remove blower unit. See BLOWER UNIT. Remove foot air duct. Disconnect PTC heater connector. Remove 2 screws and rear foot duct. Remove 4 PTC heater screws. Remove PTC heater. (Scheme 14) To install, reverse removal procedure.

Scheme 14

Disconnect pressure switch connector. Hold switch mount on tube with an open end wrench. Remove pressure switch from liquid tube. To install, reverse removal procedure.

Remove blower unit. See BLOWER UNIT . Disconnect thermistor connector. Using screwdriver, pry off thermistor. To install, reverse removal procedure.

1. Wear insulated gloves. Remove key from ignition switch. Ensure charge connector is disconnected. Disconnect negative battery cable. Remove service plug and wait 5 minutes for system to discharge. After removing service plug, cover plug connector using rubber or vinyl tape. Partially drain Hybrid Vehicle (HV) coolant and engine coolant. Remove cowl top panel.
2. Use care to prevent dirt or other foreign matter from entering inside of connector cover. Disconnect and insulate positive battery cable. Remove 4 Torx screws and inverter terminal cover. Remove 2 remaining Torx screws and remove circuit breaker sensor and connector cover. Slide connector cover to disconnect circuit breaker sensor connector. Using voltmeter, check voltage at each terminal and ensure zero volts are present.
3. Remove 6 bolts and 3 power cables. Remove 3 bolts and power cable along with converter and inverter assembly. (Scheme 15) Remove bolt and ground cable. Disconnect 3 water hoses from converter and inverter assembly. Remove 4 bolts and converter and inverter assembly.
4. Disconnect water hoses from water pump. (Scheme 16) Remove bolt and refrigerant line bracket. Remove 3 water pump bolts. Remove water pump. To install, reverse removal procedure. Push water hose onto water pump pipe as far as water pump unit and install hose clip. Bleed cooling system. See COOLING SYSTEM in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER in ENGINE PERFORMANCE.

Scheme 15

Scheme 16