Toyota Sienna 2000-06

Air Mix Servo Assemblies

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Fig. A/C unit assembly and related components (1 of 2)-2004-06 Sienna



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Fig. A/C unit assembly and related components (2 of 2)-2004-06 Sienna

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Recover the refrigerant from the A/C system using approved equipment.
  8.  
  9. Remove the wiper arms.
  10.  
  11. Remove the cowl top panel sub assembly.

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    Fig. Remove the cowl top panel sub assembly-2004-06 Sienna



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    Fig. Install tool 09870-00025 on the refrigerant pipe clamp going to the cooler unit-2004-06 Sienna



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    Fig. Disconnecting the refrigerant and suction tubes after unfastening the clamps-2004-06 Sienna

  12.  
  13. Install tool 09870-00025 on the refrigerant pipe clamp going to the cooler unit as illustrated.
  14.  
  15. Push down on the tool to unlock the clamp gently so as not to distort the tube, pull and push the release lever gently and remove the clamp to disconnect the pipe.
  16.  
  17. Disconnect the suction tube in the same manner.
  18.  
  19. Remove the air cleaner assembly.
  20.  
  21. Disconnect the hoses from the heater core.
  22.  
  23. Remove the instrument panel.
  24.  
  25. Remove the heater to foot duct No: 3 and No: 1.
  26.  
  27. Disconnect the transmission control cable assembly and set aside.
  28.  
  29. Remove the shift lock control unit.
  30.  
  31. Unfasten the retainers and remove instrument panel bracket No: 5.
  32.  
  33. Unfasten the clamps, bolt and connector to remove instrument panel brace No: 1.
  34.  
  35. Unfasten the clamps, bolt and connector to remove instrument panel brace No: 2.

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    Fig. Instrument panel bracket No: 5 mounting-2004-06 Sienna



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    Fig. Instrument panel brace No: 1 mounting-2004-06 Sienna

  36.  
  37. Remove the steering column.
  38.  
  39. Remove the ECM and stereo.
  40.  
  41. Remove the right hand fender garnish.
  42.  
  43. Unfasten all clamps, bolts nuts and electrical connectors from the instrument panel reinforcement and remove the reinforcement.

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    Fig. Location of the instrument panel reinforcement nuts, clamps and electrical connectors-2004-06 Sienna



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    Fig. Location of the instrument panel reinforcement nuts and bolts-2004-06 Sienna

  44.  
  45. Remove the lower defroster nozzle assembly.
  46.  
  47. Unfasten the nut and claw fittings and remove the A/C unit assembly.
  48.  
  49. Remove the blower motor assembly.
  50.  
  51. Unfasten the retainers and remove the mode damper servo assembly and airmix damper servo assembly.
  52.  
  53. If equipped with automatic A/C system, remove the airmix No: 2 damper servo assembly.

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    Fig. Location of the mode damper servo-2004-06 Sienna



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    Fig. Location of the airmix damper servo-2004-06 Sienna



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    Fig. Location of the airmix damper servo N0: 2 on models equipped with an automatic A/C system-2004-06 Sienna

  54.  

To install:

  1. If equipped with automatic A/C system, install the airmix No: 2 damper servo assembly.
  2.  
  3. Install the mode damper servo assembly and airmix damper servo assembly.
  4.  
  5. Install the blower motor assembly.
  6.  
  7. Temporarily tighten the A/C unit assembly nut to 30 in. lbs. (3.5 Nm), then attach the clamps.
  8.  
  9. Remove the lower defroster nozzle assembly.
  10.  
  11. Install the instrument panel reinforcement and tighten the retainers to 65 in. lbs. (7 Nm). Engage all clamps and electrical connectors.
  12.  
  13. Tighten the A/C unit assembly nuts and bolts.
  14.  
  15. Install the right hand fender garnish.
  16.  
  17. Install the ECM and stereo.
  18.  
  19. Install the steering column.
  20.  
  21. Install the instrument panel brace No: 2. Attach the clamps, bolt and connector.
  22.  
  23. Install the instrument panel brace No: 1. Attach the clamps, bolt and connector.
  24.  
  25. Install instrument panel bracket No: 5.
  26.  
  27. Install the shift lock control unit.
  28.  
  29. Disconnect the transmission control cable assembly and set aside.
  30.  
  31. Install the heater to foot duct No: 3 and No: 1.
  32.  
  33. Install the instrument panel.
  34.  
  35. Connect the hoses to the heater core.
  36.  
  37. Install the air cleaner assembly.
  38.  
  39. Install new O-rings on the suction and refrigerant pipes, lubricate the O-rings with compressor oil and install on the hose. Install the pipes and engage the clamps.

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    Fig. Make sure the clamps on the suction and refrigerant pipes are properly engaged.-2004-06 Sienna

  40.  
  41. Install the cowl top panel sub assembly.
  42.  
  43. Install the wiper arms.
  44.  
  45. Charge the refrigerant in the A/C system using approved equipment.
  46.  
  47. Fill the cooling system.
  48.  
  49. Connect the negative battery cable. Start the vehicle and check for coolant leaks and A/C leaks.
  50.  

 
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