Toyota Prius 2002-06

Instrument Panel, Pad, and Dashboard

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Removal & Installation



2002-03 Model
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the negative battery cable to prevent possible airbag and seat belt pretensioner activation.

    Click image to see an enlarged view

    Fig. Exploded view of instrument panel assembly and related components-2002-03 Prius

  4.  
  5. Remove the instrument panel as follows:
    NOTE
    If the airbag connector is disconnected with the ignition switch at ON, DTCs will be recorded.




    1. Place the front wheels facing straight ahead.
    2.  
    3. Using a Torx socket wrench, loosen the 2 Torx screws until the groove along the screw circumference catches on the screw case.
    4.  
    5. Pull out the wheel pad from the steering wheel and disconnect the airbag connector and disconnect.
      CAUTION
      When storing the wheel pad, keep the upper surface of the pad facing upward. Never disassemble the wheel pad. When removing the wheel pad, take care not to pull the airbag wire harness.

    6.  
    7. Remove the steering wheel set nut and place match marks on the steering wheel and main shaft assembly.
    8.  
    9. Using SST 09950-50013, remove the steering wheel.
    10.  
    11. Remove front door scuff plates.
    12.  
    13. Remove cowl side trims.
    14.  
    15. Remove front pillar garnishes.
    16.  
    17. Remove the 2 screws and hood lock release lever.
    18.  
    19. Zip the shifting hole cover open and remove the bolt and screw.
    20.  
    21. Using a screwdriver, remove the lower finish panel, then disconnect the connectors and DLC3.
    22.  
    23. Remove finish panel.
    24.  
    25. Remove column covers.
    26.  
    27. Disconnect the connectors, remove the 3 screws and combination switch with spiral cable.
      NOTE
      Do not disassemble the spiral cable or apply oil to it.

    28.  
    29. Rotate the stoppers of the glove compartment door to 90 degrees and pull them out inward.
    30.  
    31. Remove the 2 screws and glove compartment door.
    32.  
    33. Remove the 2 clips and, using a screwdriver, remove the lower center cluster finish panel. Disconnect the connector.
    34.  
    35. Remove glove compartment door reinforcement, if equipped.
    36.  
    37. Disconnect the passenger airbag connector and disengage the airbag connector clamp from the center bracket.
      CAUTION
      When disconnecting the airbag connector, take care not to damage the airbag wire harness.

    38.  
    39. Remove the 2 bolts and nuts and passenger airbag assembly.
      CAUTION
      Do not store the passenger airbag assembly with the airbag deployment side facing down. Never disassemble the passenger airbag assembly. Take care not to damage the wire harness.

    40.  
    41. Remove hazard warning switch, using a screwdriver and disconnect the connectors. Tape the screwdriver tip before use.
    42.  
    43. Remove radio or radio tuner opening cover.
    44.  
    45. Remove the 2 screws, and using a screwdriver, remove the cluster finish panel assembly. Disconnect the connectors.
    46.  
    47. Remove the 3 screws and combination meter. Disconnect the connector.
    48.  
    49. Remove the No. 1 and No. 2 side defroster nozzles, using a screwdriver. Tape the screwdriver tip before use.
    50.  
    51. Remove the No. 1 and No. 3 registers, using a screwdriver. Tape the screwdriver tip before use.
    52.  
    53. Remove fasteners and lower steering column from under the instrument panel
    54.  
    55. Disconnect the connectors, wire harness clamps and remove the 4 bolts, 3 screws and instrument panel.
    56.  
    57. Remove No. 1 brace.
    58.  
    59. Remove the instrument panel reinforcement.
    60.  
    61. Remove the rear console box.
    62.  

  6.  

To install:

  1. Install the instrument panel as follows:


    1. Install the rear console box.
    2.  
    3. Install the instrument panel reinforcement.
    4.  
    5. Install the No. 1 brace.
    6.  
    7. Connect the connectors, wire harness clamps and install the instrument panel. Install and tighten the 4 bolts and 3 screws.
    8.  
    9. Position steering column in place under the instrument panel and tighten the fasteners to 19 ft. lbs. (25 Nm).
    10.  
    11. Install the No. 1 and No. 3 registers.
    12.  
    13. Install the No. 1 and No. 2 side defroster nozzles.
    14.  
    15. Install the combination meter and 3 mounting screws. Engage the connectors.
    16.  
    17. Install the cluster finish panel and 2 screws.
    18.  
    19. Install radio or radio tuner opening cover.
    20.  
    21. Install hazard warning switch and connect the connectors.
    22.  
    23. Install the passenger airbag assembly.
    24.  
    25. Engage the airbag connector clamp to the center bracket and connect the passenger airbag connector.
    26.  
    27. Install glove compartment door reinforcement, if equipped.
    28.  
    29. Install the lower center cluster finish panel. Engage the connector and 2 clips.
    30.  
    31. Install the glove compartment door.
    32.  
    33. Install the combination switch with spiral cable and connect the connectors.
    34.  
    35. Install column covers.
    36.  
    37. Install finish panel.
    38.  
    39. Connect the connectors and DLC3 and install the lower finish panel.
    40.  
    41. Install the bolt and screw and close the shifting hole cover.
    42.  
    43. Install the hood lock release lever.
    44.  
    45. Install the front pillar garnishes.
    46.  
    47. Install the cowl side trims.
    48.  
    49. Install front door scuff plates.
    50.  
    51. Install the steering wheel. Torque the set nut to 37 ft. lbs. (50 Nm).
    52.  
    53. Connect the airbag connector. Install the wheel pad to the steering wheel and tighten the 2 screws to 78 inch lbs. (8.8 Nm).
    54.  

  2.  
  3. Connect the negative battery cable.
  4.  
  5. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  6.  

2004-06 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds after disconnecting the negative battery cable to prevent possible airbag and seat belt pretensioner activation.
  4.  
  5. Place front wheels in the straight ahead position.
  6.  
  7. Recover refrigerant from A/C system.
  8.  
  9. Disconnect the suction hose sub-assembly as follows:


    1. Check SST 09870-00015 installation direction. Set SST so that the stopper side is on the piping clamp lock side.
    2.  
    3. Install SST on the piping clamp.
    4.  
    5. Push down on SST with your thumb while holding the pipe with both hands. Be careful not to bend the pipe.
    6.  
    7. Pull SST until the stopper touches the pipe.
    8.  
    9. Raise SST stopper and remove the piping clamp with SST from the pipe.
    10.  
    11. Remove the piping clamp from SST.
    12.  
    13. Disconnect the suction hose by hand or using a screwdriver.
    14.  
    15. Remove the 2 O-rings from the suction hose. Do not apply excessive force to the suction hose. Seal the opening of the disconnected part using vinyl tape to prevent moisture and foreign matter from entering it.
    16.  

  10.  
  11. Disconnect the cooler refrigerant liquid pipe E (to cooler unit) by using the same procedures described for the suction hose utilizing SST 09870-00025.

    Click image to see an enlarged view

    Fig. Exploded view of instrument panel safety pad and related components-2004-06 Prius



    Click image to see an enlarged view

    Fig. Exploded view of instrument registers and related components-2004-06 Prius

  12.  
  13. Detach the 2 claws and 4 clips, and remove the instrument panel register.
  14.  
  15. Remove the 2 screws and disconnect the hood lock control cable.
  16.  
  17. Detach the 4 claws, 5 clips and disconnect all connectors and remove the instrument panel finish panel.
  18.  
  19. Detach the 3 claws, 4 clips and disconnect the connector and remove the instrument panel finish panel.
  20.  
  21. Detach the claw, 5 clips and disconnect the connector and remove the No. 3 instrument panel register.
  22.  
  23. Detach the 6 clips and remove the No. 4 instrument panel register.
  24.  
  25. Detach the 2 claws and 4 clips, and remove the No. 2 instrument panel register.
  26.  
  27. Remove the multi-display assembly.
  28.  
  29. Remove the glove compartment door stopper from the glove compartment door.
  30.  
  31. While pushing in the sides of the glove compartment door, open the door to release it from the 2 stoppers.
  32.  
  33. Open the door until it is horizontal.
  34.  
  35. Pull the glove compartment door toward the rear of the vehicle to detach the 2 hinges and remove the glove compartment door.
  36.  
  37. Remove the instrument panel cushion.
  38.  
  39. Remove the instrument cluster finish panel end.
  40.  
  41. Using a screwdriver, remove the 2 instrument panel hole covers.
  42.  
  43. Remove the 2 screws, detach the claw and 2 clips, and remove the glove compartment door.
  44.  
  45. Remove the No. 1 instrument panel speaker sub-assembly (w/ JBL Sound System).
  46.  
  47. Remove the left and right front pillar garnish corner pieces.
  48.  
  49. Remove the left and right front pillar garnishes.
  50.  
  51. Disconnect the passenger airbag connector.
  52.  
  53. Remove the 3 screws, 2 bolts, pull up the instrument panel to detach the 6 claws and 3 clips.
  54.  
  55. Remove the instrument panel safety pad.

    Click image to see an enlarged view

    Fig. Exploded view of lower instrument panel, steering wheel and related components-2004-06 Prius



    Click image to see an enlarged view

    Fig. Exploded view of lower instrument panel assembly-2004-06 Prius

  56.  
  57. Remove the N0. 2 and No. 3 steering wheel lower covers.
  58.  
  59. Remove the steering pad assembly.
  60.  
  61. Remove the steering wheel.
  62.  
  63. Remove the tilt lever bracket.
  64.  
  65. Remove the steering column cover.
  66.  
  67. Remove the spiral cable sub-assembly.
  68.  
  69. Remove left and right front door scuff plates.
  70.  
  71. Remove left and right cowl side trim boards.
  72.  
  73. Remove the 2 screws, detach the 4 clips and remove the instrument cluster finish panel.
  74.  
  75. Remove the No. 1 center cluster cushion.
  76.  
  77. Remove the radio receiver.
  78.  
  79. Using a clip remover, remove the clip from the instrument panel finish panel lower center.
  80.  
  81. Detach the 4 claws and 2 clips, and remove the instrument panel finish panel.
  82.  
  83. Detach the 6 claws and remove the glove compartment door lock cover.
  84.  
  85. Remove the 4 screws and glove compartment door lock.
  86.  
  87. Detach the 4 claws and remove the instrument panel finish panel lower.
  88.  
  89. Detach the 2 claws and remove the No. 1 instrument panel under cover.
  90.  
  91. Remove power steering ECU.
  92.  
  93. Remove the shift lever assembly lower.
  94.  
  95. Using a clip remover, remove the 8 clips from the duct and lower instrument panel.
  96.  
  97. Remove the 6 bolts, 2 screws, disconnect all connectors, and detach all clamps.
  98.  
  99. Remove the instrument panel lower sub-assembly.
  100.  
  101. Fold back the floor carpet so that the No. 3 air duct rear can be removed.
  102.  
  103. Detach the 10 claws and then remove the No. 3 air duct rear.
  104.  
  105. Remove the clip and No. 3 heater to register duct with the No. 2 side defroster nozzle duct.
  106.  
  107. Remove the No. 1 duct with the No. 1 side defroster nozzle duct.
  108.  
  109. Remove the No. 2 heater-to-register duct.
  110.  
  111. Remove the 2 clips, detach the 3 claws and then remove the defroster nozzle.
  112.  
  113. Remove the transaxle control ECU assembly.
  114.  
  115. Remove the ECM.
  116.  
  117. Remove the network gateway ECU.
  118.  
  119. Detach the clamp and disconnect the harness.
  120.  
  121. Remove the 2 bolts, nut and instrument panel brace.
  122.  
  123. Remove the air conditioning amplifier assembly by disconnecting the connector and removing the 2 screws.
  124.  
  125. Separate steering column from under the lower instrument panel.
  126.  
  127. Disconnect each connector and remove each clamp. Disconnect the wire harness.
  128.  
  129. Remove the 7 bolts, 2 nuts and then remove the instrument panel reinforcement with the air conditioner unit.

    Click image to see an enlarged view

    Fig. Exploded view of A/C unit and related components-2004-06 Prius

  130.  
  131. Remove the air conditioning unit assembly as follows:


    1. Disconnect the 5 connectors.
    2.  
    3. Detach the 9 clamps and disconnect the wire harness.
    4.  
    5. Remove the bolt.
    6.  
    7. Detach the clamp and disconnect the junction connector.
    8.  
    9. Remove the 2 screws and air conditioning unit from the instrument panel reinforcement.
    10.  

  132.  

To install:

  1. Install the air conditioning unit assembly as follows:


    1. Install the air conditioning unit to the instrument panel reinforcement with the 2 screws. Use repair screws (part No. 90159-70003) if the screws removed before cannot be tightened.
    2.  
    3. Attach the clamp to connect the junction connector.
    4.  
    5. Install the bolt.
    6.  
    7. Attach the 9 clamps to connect the wire harness.
    8.  
    9. Connect the 5 connectors.
    10.  

  2.  
  3. Install the instrument panel reinforcement with the 7 bolts.
  4.  
  5. Install the 2 nuts to the air conditioning unit and temporarily tighten them.
  6.  
  7. Connect each connector and install each clamp. Then connect the wire harness.
  8.  
  9. Install the air conditioning amplifier assembly with the 2 screws and engage the connector.
  10.  
  11. Place steering column into position underneath the lower instrument panel and tighten the mounting bolts.
  12.  
  13. Install the instrument panel brace with the 2 bolts and nut.
  14.  
  15. Attach the clamp to connect the harness.
  16.  
  17. Fully tighten the air conditioning unit with the 2 nuts. Tighten the left nut first, then the right nut second.
  18.  
  19. Install the network gateway ECU.
  20.  
  21. Install the ECM.
  22.  
  23. Install the transaxle control ECU assembly.
  24.  
  25. Install the defroster nozzle and attach the 3 claws.
  26.  
  27. Install the 2 clips.
  28.  
  29. Install the No. 2 heater-to-register duct.
  30.  
  31. Install the duct with the No. 1 side defroster nozzle duct.
  32.  
  33. Install the clip and then the duct with the No. 2 side defroster nozzle duct.
  34.  
  35. Attach the 10 claws to install the No. 3 air duct rear, then return the carpet to its original position.
  36.  
  37. Install the lower instrument panel sub-assembly.
  38.  
  39. Connect all the connectors and attach all the clamps.
  40.  
  41. Install the 2 screws, 6 bolts, 8 clips to the duct and lower instrument panel.
  42.  
  43. Install the lower shift lever assembly.
  44.  
  45. Install the power steering ECU.
  46.  
  47. Attach the 2 claws to install the No. 1 instrument panel under cover.
  48.  
  49. Attach the 4 claws to install the instrument panel finish panel.
  50.  
  51. Install the glove compartment door lock with the 4 screws.
  52.  
  53. Attach the 6 claws to install the glove compartment door lock cover.
  54.  
  55. Attach the 4 claws and 2 clips to install the instrument panel finish panel lower center. Install the clip.
  56.  
  57. Install the radio receiver.
  58.  
  59. Install the No. 1 center cluster cushion.
  60.  
  61. Attach the 4 claws and 2 clips to install the instrument cluster finish panel assembly center. Install the 2 screws.
  62.  
  63. Install left and right cowl side trim boards.
  64.  
  65. Install left and right front door scuff plates.
  66.  
  67. Install the spiral cable sub-assembly.
  68.  
  69. Install the steering column cover.
  70.  
  71. Install the tilt lever bracket.
  72.  
  73. Install the steering wheel and tighten the center nut to 37 ft. lbs. (50 Nm).
  74.  
  75. Install the steering pad assembly.
  76.  
  77. Install the N0. 2 and No. 3 steering wheel lower covers.
  78.  
  79. Attach the 6 claws and 3 clips to install the instrument panel safety pad. Install the 2 bolts and 3 screws.
  80.  
  81. Connect the passenger airbag connector.
  82.  
  83. Install left and right front pillar garnishes.
  84.  
  85. Install left and right front pillar garnish corner pieces.
  86.  
  87. Install the No. 1 instrument panel speaker sub-assembly (w/ JBL Sound System).
  88.  
  89. Attach the claw and 2 clips to install the glove compartment door. Install the 2 screws.
  90.  
  91. Install the 2 instrument panel hole covers.
  92.  
  93. Install the instrument cluster finish panel end.
  94.  
  95. Install the instrument panel cushion.
  96.  
  97. Attach the 2 hinges to install the glove compartment door.
  98.  
  99. While pushing in the sides of the glove compartment door, engage it to the 2 stoppers.
  100.  
  101. Install glove compartment door stopper sub-assembly.
  102.  
  103. Install the multi-display assembly.
  104.  
  105. Attach the 2 claws and 4 clips to install the No. 2 instrument panel register.
  106.  
  107. Attach the 6 clips to install the No. 4 instrument panel register.
  108.  
  109. Connect the connector, attach the claw and 5 clips to install the No. 3 instrument panel register.
  110.  
  111. Connect the connector, attach the 3 claws and 4 clips to install the upper instrument panel finish panel.
  112.  
  113. Connect the connectors, attach the 4 claws and 5 clips to install the lower instrument panel finish panel.
  114.  
  115. Connect the hood lock control cable and install the 2 screws.
  116.  
  117. Attach the 2 claws and 4 clips to install the instrument panel register.
  118.  
  119. Connect the cooler refrigerant liquid pipe E (to cooler unit) as follows:


    1. Remove the attached vinyl tape from the pipe's disconnected part.
    2.  
    3. Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the pipe's connecting part.
      CAUTION
      Do not use any compressor oil other than ND-OIL 11. If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4.  
    5. Install the O-rings to the pipe.
    6.  
    7. Insert the pipe joint into the cooler unit fitting hole securely.
    8.  
    9. Using the piping clamp, connect the cooler unit refrigerant liquid pipe E. Ensure that the piping clamp is securely engaged.
    10.  

  120.  
  121. Connect the suction hose sub-assembly by using the same procedures described for the cooler unit refrigerant liquid pipe E.
  122.  
  123. Evacuate and recharge the refrigerant.
  124.  
  125. Connect the negative battery cable.
  126.  
  127. Operate the engine to normal operating temperatures; then, check the climate control operation and check for coolant and refrigerant leaks.
  128.  
  129. Perform calibration.
  130.  
  131. Perform initialization.
  132.  
  133. Check the SRS warning light.
  134.  

 
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