Toyota Sienna 2000-06

Heater Core

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Removal & Installation



  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. Disconnect the heater radiator pipes.
  8.  
  9. Remove the front seats, front door scuff plates and cowl side trims.
  10.  
  11. Remove the rear door scuff plates, lower door scuff plates and rear console box.
  12.  
  13. Remove the rear outlet grill on the left side.
  14.  
  15. Slide the carpet back and remove the two clips and air outlet grill from the rear heater.
  16.  
  17. Remove the bolts, clips and rear air duct.
  18.  
  19. Unplug the connectors and remove the rear heater unit.
  20.  
  21. Remove the blower resistor on manual A/C control unit models or the power transistor if equipped with an automatic A/C control assembly.
  22.  
  23. If equipped with an automatic control assembly, remove the air inlet temperature sensor.
  24.  
  25. Remove the air mix servometer.
  26.  
  27. Remove the screws, clamps and plate, then remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the rear heater core assembly and related components-2000-03 Sienna

  28.  

To install:

  1. Install the heater core, plate screws and clamps.
  2.  
  3. Install the servometer.

    Click image to see an enlarged view

    Fig. The rear heater core is located inside the rear heater case-2000-03 Sienna

  4.  
  5. Install the temperature sensor, power transistor or blower resistor as equipped.
  6.  
  7. Install the rear air duct, outlet grill, clips and carpet.
  8.  
  9. Install the left outlet grill, rear console box, scuff plates, side trims and seats.
  10.  
  11. Attach the pipes to the heater radiator, push the hose onto the pipe as far as the second ridge on the pipe and install the clamps.
  12.  
  13. Fill the cooling system, start the vehicle, allow to reach operating system; turn on the rear heat and check for leaks.

    Click image to see an enlarged view

    Fig. Attach the pipes to the rear heater radiator, push the hose onto the pipe as far as the second ridge on the pipe-2000-03 Sienna

  14.  

  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. Evacuate the A/C system using approved equipment.
  8.  
  9. Remove the scuff plates from the back door and right hand rear door.
  10.  
  11. Remove the quarter trim panel garnish.
  12.  
  13. Remove the rear headliner garnish.
  14.  
  15. Remove the rear right window side garnish assembly.
  16.  
  17. Unfasten the clips and remove the rear air duct.
  18.  
  19. Unfasten the claw retainers and remove the cover sub assembly.
  20.  
  21. Remove the air duct assembly.
  22.  
  23. Unfasten the heater hose clamp and disconnect the heater hose.
  24.  
  25. Unfasten the 2 bolts and disconnect the A/C tube and accessory assembly.
  26.  
  27. Unfasten the connectors and clamps, unplug the wiring harness and remove the blower assembly.
  28.  
  29. Unfasten the bolts and remove the blower assembly.
  30.  
  31. Unfasten the claw fittings and clamp, then remove cooler thermistor No: 1.
  32.  
  33. Unfasten the screws and remove the cooling unit motor with the fan.
  34.  
  35. Remove the blower motor resistor transistor.
  36.  
  37. Remove the rear heater core unit as follows:
    1. Unfasten the claw fittings, the 3 screws and the blower case.
    2.  
    3. Remove the screws and clamps.
    4.  
    5. Remove the screws and the heater water valve. Remove the O-rings from the valve.
    6.  
    7. Remove the heater core.

      Click image to see an enlarged view

      Fig. Unfasten the claw fittings, the 3 screws and the blower case-2004-06 Sienna



      Click image to see an enlarged view

      Fig. Remove the screws and clamps-2004-06 Sienna



      Click image to see an enlarged view

      Fig. Remove the screws and the heater water valve-2004-06 Sienna

    8.  

  38.  

To install:

  1. Install the heater core.
  2.  
  3. Install new O-rings on the water valve, install the valve and the screws.
  4.  
  5. Install the valve screws and clamps.
  6.  
  7. Install the blower case.
  8.  
  9. Install the blower motor resistor.
  10.  
  11. Install the cooling fan motor assembly with the fan.
  12.  
  13. Install the No: 1 thermistor.
  14.  
  15. Install the remaining components in the reverse order of removal.
  16.  
  17. Recharge the A/C system.
  18.  
  19. Fill the cooling system, start the vehicle, allow to reach operating system; turn on the rear heat and check for leaks.
  20.  

 
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