Toyota Highlander 6 2001-06

Removal & Installation

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CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  6.  
  7. Remove the steering wheel by performing the following procedure:
    1. Position the front wheels facing straight-ahead.
    2.  
    3. Remove the steering wheel side covers.
    4.  
    5. Using a Torx® wrench, loosen the 2 screws located at each side of the steering wheel until the screw-s circumference groove catches on the screw case.
    6.  
    7. Pull the air bag module from the steering wheel and disconnect the electrical connector.
      CAUTION
      Place the air bag module in a safe place with the front side facing upward.

    8.  
    9. Remove the steering wheel nut.
    10.  
    11. Place alignment marks on the steering wheel and the main shaft.
    12.  
    13. Using a steering wheel puller, press the steering wheel from the steering column.
    14.  

  8.  
  9. Remove the instrument panel and reinforcement by performing the following procedure:
    1. Remove the front door scuff plates.
    2.  
    3. Remove the cowl side boards.
    4.  
    5. Remove the front door trim covers.
    6.  
    7. Remove the front pillar garnish by disengaging the 5 clips. If equipped with a tweeter speaker, disconnect the electrical connector.
    8.  
    9. Remove the steering column covers-to-steering column screws and the covers.
    10.  
    11. Remove the combination switch-to-steering column screws, disconnect the electrical connector(s) and remove the combination switch.
    12.  
    13. Remove the 2 hood open lever screws and the hood open lever.
    14.  
    15. Remove the 2 lower finish panel bolts and disengage the panel from the 3 clips.
    16.  
    17. Remove the 2 No. 1 safety pad insert bolts and the insert.
    18.  
    19. Remove the 2 No. 2 finish panel bolts and disengage the panel from the 4 clips.
    20.  
    21. In the left side of the glove compartment, pry out the glove box door finish plate and disconnect the air bag module connector.
    22.  
    23. Remove the glove box 3 nuts and 2 screws and the glove box.
    24.  
    25. Remove the center cluster finish panel by disengaging the claw (bottom center) and 4 clips (1 at each corner).
    26.  
    27. Remove the ashtray, the 2 ashtray receptacle box screws.
    28.  
    29. Remove the 4 lower center cluster finish panel screws and disconnect the connector.
    30.  
    31. Remove the clock, the No. 1 and No. 2 registers from the panel.
    32.  
    33. Remove the 3 cluster finish panel screws, disengage the 8 clips and remove the panel.
    34.  
    35. Remove the combination meter.
    36.  
    37. Remove the radio assembly.
    38.  
    39. Remove the heater control assembly.
    40.  
    41. Remove 2 passenger-s side air bag module bolts; then, disconnect and remove the air bag module.
      CAUTION
      Place the air bag module in a safe place with the front side facing upward.

    42.  
    43. Remove the instrument panel-to-chassis 5 bolts and nut.
    44.  
    45. Remove the audio amplifier.
    46.  
    47. Remove the No. 1 and No. 2 braces.
    48.  
    49. Remove the No. 2 cowl brace.
    50.  
    51. Remove the instrument panel reinforcement.
    52.  

  10.  
  11. Remove the evaporator housing by performing the following procedure:
    1. Discharge and recover the air conditioning system refrigerant.
    2.  
    3. In the engine compartment, remove the refrigerant lines-to-cowl connector bolts; then, disconnect the lines and discard the O-rings.
    4.  
    5. Disconnect the electrical connector at the evaporator housing.
    6.  
    7. Disconnect the wiring harness clamp.
    8.  
    9. Remove the evaporator housing-to-chassis 2 rivets, 3 bolts and nut.
    10.  
    11. Remove the evaporator housing.
    12.  

  12.  
  13. Remove the 4 defroster nozzle nuts and the nozzle.
  14.  
  15. Disconnect and remove the theft deterrent and the wireless door lock ECUs.
  16.  
  17. Release the 2 air duct claws and the air duct.
  18.  
  19. Remove the 2 heater housing-to-chassis rivets and the heater housing.
    NOTE
    When installing the heater housing, use new screws in place of the rivets.

  20.  
  21. Remove the heater core-to-heater housing cover.
  22.  
  23. Remove both heater core screws and clamps; then, remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel, steering column and related components-Highlander



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-Highlander



    Click image to see an enlarged view

    Fig. Exploded view of the ventilation system and related components-Highlander



    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing, evaporator housing and related components-Highlander

  24.  

To install:

  1. Install the heater core and both heater core screws and clamps.
  2.  
  3. Install the heater core-to-heater housing cover.
    NOTE
    When installing the heater housing, use new screws in place of the rivets.

  4.  
  5. Install the heater housing-to-chassis and the 2 heater housing screws.
  6.  
  7. Release the air duct and the air duct claws.
  8.  
  9. Connect and install the theft deterrent and the wireless door lock ECUs.
  10.  
  11. Install the defroster nozzle and the 4 nozzle nuts.
  12.  
  13. Install the evaporator housing by performing the following procedure:
    1. Install the evaporator housing.
    2.  
    3. Install the evaporator housing-to-chassis 2 rivets, 3 bolts and nut.
    4.  
    5. Connect the wiring harness clamp.
    6.  
    7. Connect the electrical connector at the evaporator housing.
    8.  
    9. In the engine compartment, use new O-rings and install the refrigerant lines-to-cowl connector and install the bolts.
    10.  

  14.  
  15. Install the instrument panel and reinforcement by performing the following procedure:
    1. Install the instrument panel reinforcement.
    2.  
    3. Install the No. 2 cowl brace.
    4.  
    5. Install the No. 1 and No. 2 braces.
    6.  
    7. Install the audio amplifier.
    8.  
    9. Install the instrument panel-to-chassis 5 bolts and nut.
    10.  
    11. Connect and install the air bag module and the 2 passenger-s side air bag module bolts.
    12.  
    13. Install the heater control assembly.
    14.  
    15. Install the radio assembly.
    16.  
    17. Install the combination meter.
    18.  
    19. Install the cluster finish panel, engage the 8 clips and install the panel screws.
    20.  
    21. Install the No. 1 and No. 2 registers and the clock to the panel.
    22.  
    23. Connect the lower center cluster finish panel connector and install the 4 lower center cluster finish panel screws.
    24.  
    25. Install the 2 ashtray receptacle box screws and the ashtray.
    26.  
    27. Install the center cluster finish panel by engaging the 4 clips (1 at each corner) and the claw (bottom center).
    28.  
    29. Install the glove box and the glove box 3 nuts and 2 screws.
    30.  
    31. In the left side of the glove compartment, connect the air bag module connector and install the glove box door finish plate.
    32.  
    33. Install the No. 2 finish panel, engage the 4 panel clips and install the 3 panel bolts.
    34.  
    35. Install the No. 1 safety pad insert and the 2 insert bolts.
    36.  
    37. Install the finish panel, engage the 3 finish panel clips and install 2 lower finish panel bolts.
    38.  
    39. Install the hood open lever and the 2 hood open lever screws.
    40.  
    41. Install the combination switch, connect the electrical connector(s) and install the combination switch-to-steering column screws.
    42.  
    43. Install the steering column covers and the covers-to-steering column screws.
    44.  
    45. Install the front pillar garnish by engaging the 5 clips. If equipped with a tweeter speaker, connect the electrical connector.
    46.  
    47. Install the front door trim covers.
    48.  
    49. Install the cowl side boards.
    50.  
    51. Install the front door scuff plates.
    52.  

  16.  
  17. Install the steering wheel by performing the following procedure:
    1. Install the steering wheel to the steering column.
    2.  
    3. Align the steering wheel-to-main shaft marks.
    4.  
    5. Install the steering wheel nut and torque the nut to 25 ft. lbs. (34 Nm).
    6.  
    7. Install the air bag module to the steering wheel and connect the electrical connector.
    8.  
    9. Using a Torx® wrench, tighten the steering wheel screws to 78 inch lbs. (8.8 Nm).
    10.  
    11. Install the steering wheel side covers.
    12.  

  18.  
  19. Connect the heater hoses to the heater core.
  20.  
  21. Refill the cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Evacuate and charge the air conditioning system.
  26.  
  27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  28.  

Highlander Hybrid




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Discharge and recover the refrigerant from the A/C system.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    Wait 90 seconds after disconnect the cable to allow the airbag to discharge.

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Wiper arms
     
    Cowl top ventilator louver assembly
     
    Wiper link assembly
     
    Air conditioning tube and accessory assembly
     
    Cooler refrigerant suction hose No.1
     
    Heater hoses from the heater core.
     

  8.  
  9. Remove the instrument panel assembly as follows:
    1. Remove the shift knob and console panel.
    2.  
    3. Remove the lower instrument panel.
    4.  
    5. Remove the radio.
    6.  
    7. Remove the multi-display unit.
    8.  
    9. Remove the steering wheel lower covers.
    10.  
    11. Using a Torx® wrench, loosen the 2 screws located at each side of the steering wheel until the screw-s circumference groove catches on the screw case
    12.  
    13. Pull the air bag module from the steering wheel and disconnect the electrical connector.
      CAUTION
      Place the air bag module in a safe place with the front side facing upward.

    14.  
    15. Disconnect the horn connector.
    16.  
    17. Remove the steering pad.
    18.  
    19. Matchmark the steering wheel and main shaft assembly.
    20.  
    21. Using Special Tool 00950-50013, remove the steering wheel assembly.

      Click image to see an enlarged view

      Fig. Using the special tool to remove the steering wheel assembly-RX 400h, Highlander Hybrid similar

    22.  
    23. Remove the steering column cover.
    24.  
    25. Remove the tilt and telescopic switch.
    26.  
    27. Remove the turn signal switch assembly with spiral cable assembly.
    28.  
    29. Remove the left-hand cowl side trim sub-assembly.
    30.  
    31. Remove the lower instrument panel.
    32.  
    33. Remove the driver side knee airbag assembly.
    34.  
    35. Remove the gauge cluster trim.
    36.  
    37. Remove the instrument gauge assembly.
    38.  
    39. Remove the right-hand front door scuff plate.
    40.  
    41. Remove the right-hand cowl side trim assembly.
    42.  
    43. Remove the instrument panel No. 2 under cover.
    44.  
    45. Remove the glove compartment door assembly.
    46.  
    47. Remove the center console carpet.
    48.  
    49. Remove the lower center instrument panel.
    50.  
    51. Remove the A-pillar trim.
    52.  
    53. Remove the instrument panel finish plate.
    54.  
    55. Remove the No.1 register panel.
    56.  
    57. Remove the instrument panel assembly.

      Click image to see an enlarged view

      Fig. Disconnect each of the clamps and connectors to remove the instrument panel assembly.

    58.  

  10.  
  11. Remove the hybrid vehicle control ECU.
  12.  
  13. Remove the air conditioner amplifier assembly.
  14.  
  15. Remove the rear air ducts.
  16.  
  17. Remove air duct No.1.
  18.  
  19. Remove the No.4 instrument panel bracket.
  20.  
  21. Remove the No.1 instrument panel brace.
  22.  
  23. Remove the No.2 instrument panel brace.
  24.  
  25. Matchmark and separate the steering intermediate shaft sub-assembly.
  26.  
  27. Remove the steering column assembly.
  28.  
  29. Remove the No.1 air duct sub-assembly.
  30.  
  31. Remove the instrument panel reinforcement assembly.

    Click image to see an enlarged view

    Fig. Remove the 9 bolts and 2 nuts to remove the instrument panel reinforcement assembly.

  32.  
  33. Remove the air conditioner unit.
  34.  
  35. Remove the No.2 air duct.
  36.  
  37. Remove the blower assembly.
  38.  
  39. Remove the heater to register center duct.
  40.  
  41. Remove the air outlet control servo motor.
  42.  
  43. Remove the air mix control servo motor.
  44.  
  45. Remove the evaporator temperature sensor.
  46.  
  47. Remove the heater core.

    Click image to see an enlarged view

    Fig. Remove the heater core from the air conditioner unit.

  48.  
  49. Installation is the reverse order of removal.
  50.  
  51. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  52.  

 
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