Toyota Sienna 2000-06

Removal & Installation 3

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Sienna



Removal & Installation
Front Heater
  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 (one 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-Toyota Sienna



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

  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.  

  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 (one 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-Toyota Sienna



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

  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.  

Rear Auxiliary Heater
  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 rear heater core.
  6.  
  7. Remove the front seats.
  8.  
  9. Remove the front door scuff plates.
  10.  
  11. Remove the cowl side trim.
  12.  
  13. Remove the rear door scuff plates.
  14.  
  15. Remove the lower door scuff plates.
  16.  
  17. Remove the rear console box.
  18.  
  19. Remove the left side air outlet grille.
  20.  
  21. Pull the carpet rearward.
  22.  
  23. Remove the 3 clips and the air outlet grille.
  24.  
  25. Remove the rear air duct 2 bolts, 2 clips and the duct.
  26.  
  27. Disconnect the electrical connectors.
  28.  
  29. Remove the 3 rear heater housing bolts and the housing.
  30.  
  31. Remove both heater core-to-heater housing screws and clamps.
  32.  
  33. Remove the heater core-to-heater housing screw and plate.
  34.  
  35. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the rear heater core, the rear heater housing and related components-Toyota Sienna

  36.  

To install:

  1. Install the heater core.
  2.  
  3. Install the heater core-to-heater housing screw and plate.
  4.  
  5. Install both heater core-to-heater housing screws and clamps.
  6.  
  7. Install the rear heater housing and the 3 housing bolts.
  8.  
  9. Connect the electrical connectors.
  10.  
  11. Install the rear air duct and the 2 bolts and 2 clips.
  12.  
  13. Install the 3 clips and the air outlet grille.
  14.  
  15. Move the carpet forward.
  16.  
  17. Install the left side air outlet grille.
  18.  
  19. Install the rear console box.
  20.  
  21. Install the lower door scuff plates.
  22.  
  23. Install the rear door scuff plates.
  24.  
  25. Install the cowl side trim.
  26.  
  27. Install the front door scuff plates.
  28.  
  29. Install the front seats.
  30.  
  31. Connect the heater hoses to the rear heater core.
  32.  
  33. Refill the cooling system.
  34.  
  35. Connect the negative battery cable.
  36.  

  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 rear heater core.
  6.  
  7. Remove the front seats.
  8.  
  9. Remove the front door scuff plates.
  10.  
  11. Remove the cowl side trim.
  12.  
  13. Remove the rear door scuff plates.
  14.  
  15. Remove the lower door scuff plates.
  16.  
  17. Remove the rear console box.
  18.  
  19. Remove the left side air outlet grille.
  20.  
  21. Pull the carpet rearward.
  22.  
  23. Remove the 3 clips and the air outlet grille.
  24.  
  25. Remove the rear air duct 2 bolts, 2 clips and the duct.
  26.  
  27. Disconnect the electrical connectors.
  28.  
  29. Remove the 3 rear heater housing bolts and the housing.
  30.  
  31. Remove both heater core-to-heater housing screws and clamps.
  32.  
  33. Remove the heater core-to-heater housing screw and plate.
  34.  
  35. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the rear heater core, the rear heater housing and related components-Toyota Sienna

  36.  

To install:

  1. Install the heater core.
  2.  
  3. Install the heater core-to-heater housing screw and plate.
  4.  
  5. Install both heater core-to-heater housing screws and clamps.
  6.  
  7. Install the rear heater housing and the 3 housing bolts.
  8.  
  9. Connect the electrical connectors.
  10.  
  11. Install the rear air duct and the 2 bolts and 2 clips.
  12.  
  13. Install the 3 clips and the air outlet grille.
  14.  
  15. Move the carpet forward.
  16.  
  17. Install the left side air outlet grille.
  18.  
  19. Install the rear console box.
  20.  
  21. Install the lower door scuff plates.
  22.  
  23. Install the rear door scuff plates.
  24.  
  25. Install the cowl side trim.
  26.  
  27. Install the front door scuff plates.
  28.  
  29. Install the front seats.
  30.  
  31. Connect the heater hoses to the rear heater core.
  32.  
  33. Refill the cooling system.
  34.  
  35. Connect the negative battery cable.
  36.  

T-100



Removal & Installation

NOTE
If equipped with a theft-deterrent system, be sure to acquire code. Also, write down the frequencies of the preset radio push buttons so the audio system may be reprogrammed.

  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, be sure to wait at least 1 1 / 2 minutes so that the air bag module can deplete its energy.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Remove the front pillar garnish, the front door scuff plate and the cowl side trim.
  10.  
  11. Remove the steering wheel by performing the following procedure:
    1. Position the front wheels in the straight-ahead position.
    2.  
    3. At both sides of the steering wheel, remove the side covers.
    4.  
    5. Using a Torx® wrench, loosen the steering wheel Torx® screws until the screw-s circumference ring catches on the screw case.
    6.  
    7. Carefully, lift the air bag module, disconnect the electrical connector and remove the air bag.
      CAUTION
      Place the air bag module in a safe location with the front facing upward.

    8.  
    9. Remove the steering wheel nut.
    10.  
    11. Using a steering wheel puller, press the steering wheel from the steering column.
    12.  

  12.  
  13. Remove the instrument panel by performing the following procedure:
    1. Remove the steering column cover screws and the cover.
    2.  
    3. Remove the hood lock release lever.
    4.  
    5. Remove the No. 1 lower finish panel.
    6.  
    7. Remove the combination switch.
    8.  
    9. Remove the glove compartment door.
    10.  
    11. Remove the No. 2 lower finish panel.
    12.  
    13. Remove the lower center cover.
    14.  
    15. Remove the rear console box.
    16.  
    17. Remove the heater control knobs; then, pry out the center cluster finish panel.
    18.  
    19. Remove the radio and the heater control assembly.
    20.  
    21. Remove the 2 center cluster finish lower panel screws and the panel; then, disconnect the connector.
    22.  
    23. Remove the stereo opening cover.
    24.  
    25. Remove the 5 cluster finish panel screws and the combination meter.
    26.  
    27. Remove the No. 1 register.
    28.  
    29. Remove the heater ducts from the No.1 and No. 2 registers.
    30.  
    31. Remove the glove compartment door reinforcement.
    32.  
    33. Remove the No. 1 and No. 2 brace.
    34.  
    35. Remove the instrument panel electrical connectors.
    36.  
    37. Remove the 2 instrument panel bolts and the instrument panel.
    38.  
    39. Remove the instrument panel reinforcement.
    40.  

  14.  
  15. Remove the evaporator housing by performing the following procedure:
    1. Disconnect the refrigerant lines from the evaporator housing; then, discard the O-rings and plug the openings to prevent contamination.
    2.  
    3. Remove the evaporator-to-chassis grommets.
    4.  
    5. Remove the drain pipe grommet.
    6.  
    7. Disconnect the connectors to the evaporator housing.
    8.  
    9. Remove the 5 evaporator housing-to-chassis screws, the nut and the evaporator housing.
    10.  

  16.  
  17. Disconnect the control cables from the heater housing.
  18.  
  19. Remove the heater housing-to-No. 4 register duct screw and the duct.
  20.  
  21. Remove the heater housing-to-center register duct screw and the duct.
  22.  
  23. Remove the heater housing-to-foot air duct screw and the duct.
  24.  
  25. Remove the 2 heater housing-to-chassis bolts/nut and the heater housing.
  26.  
  27. Remove the 3 heater core-to-heater housing screws, plates and clamp.
  28.  
  29. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. View of the driver-s side air bag module Torx® screws-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and air bag module assembly-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel assembly-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel registers and braces-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, heater core, heater housing and evaporator housing assembly-Toyota T-100

  30.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install the 3 heater core-to-heater housing screws, plates and clamp.
  4.  
  5. Install the heater housing and the 2 heater housing-to-chassis bolts/nut.
  6.  
  7. Install the heater housing-to-foot air duct and the duct screw.
  8.  
  9. Install the heater housing-to-center register duct and the duct screw.
  10.  
  11. Install the heater housing-to-No. 4 register duct and the duct screw.
  12.  
  13. Connect the control cables to the heater housing.
  14.  
  15. Install the evaporator housing by performing the following procedure:
    1. Install the evaporator housing, the nut and the 5 evaporator housing-to-chassis screws.
    2.  
    3. Connect the connectors to the evaporator housing.
    4.  
    5. Install the drain pipe grommet.
    6.  
    7. Install the evaporator-to-chassis grommets.
    8.  
    9. Using new O-rings, connect the refrigerant lines to the evaporator housing.
    10.  

  16.  
  17. Install the instrument panel by performing the following procedure:
    1. Install the instrument panel reinforcement.
    2.  
    3. Install the instrument panel and the 2 instrument panel bolts.
    4.  
    5. Install the instrument panel electrical connectors.
    6.  
    7. Install the No. 1 and No. 2 brace.
    8.  
    9. Install the glove compartment door reinforcement.
    10.  
    11. Install the heater ducts to the No.1 and No. 2 registers.
    12.  
    13. Install the No. 1 register.
    14.  
    15. Install the combination meter and the 5 cluster finish panel screws.
    16.  
    17. Install the stereo opening cover.
    18.  
    19. Connect the connector; then, install the center cluster finish lower panel and the 2 panel screws.
    20.  
    21. Install the heater control assembly and the radio.
    22.  
    23. Install the center cluster finish panel and the heater control knobs.
    24.  
    25. Install the rear console box.
    26.  
    27. Install the lower center cover.
    28.  
    29. Install the No. 2 lower finish panel.
    30.  
    31. Install the glove compartment door.
    32.  
    33. Install the combination switch.
    34.  
    35. Install the No. 1 lower finish panel.
    36.  
    37. Install the hood lock release lever.
    38.  
    39. Install the steering column cover and the cover screws.
    40.  

  18.  
  19. Install the steering wheel by performing the following procedure:
    1. Install the steering wheel to the steering column.
    2.  
    3. Install the steering wheel nut and torque it to 26 ft. lbs. (35 Nm).
    4.  
    5. Carefully, install the air bag module and connect the electrical connector.
    6.  
    7. Using a Torx® wrench, tighten the steering wheel screws to 78 inch lbs. (9.0 Nm).
    8.  
    9. At both sides of the steering wheel, install the side covers.
    10.  

  20.  
  21. Install the front pillar garnish, the front door scuff plate and the cowl side trim.
  22.  
  23. Connect the heater hoses to the heater core.
  24.  
  25. Refill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Evacuate and charge the air conditioning system.
    NOTE
    If equipped with a theft-deterrent system, enter the code and reprogram the radio.

  30.  
  31. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  32.  


NOTE
If equipped with a theft-deterrent system, be sure to acquire code. Also, write down the frequencies of the preset radio push buttons so the audio system may be reprogrammed.

  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, be sure to wait at least 1 1 / 2 minutes so that the air bag module can deplete its energy.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Remove the front pillar garnish, the front door scuff plate and the cowl side trim.
  10.  
  11. Remove the steering wheel by performing the following procedure:
    1. Position the front wheels in the straight-ahead position.
    2.  
    3. At both sides of the steering wheel, remove the side covers.
    4.  
    5. Using a Torx® wrench, loosen the steering wheel Torx® screws until the screw-s circumference ring catches on the screw case.
    6.  
    7. Carefully, lift the air bag module, disconnect the electrical connector and remove the air bag.
      CAUTION
      Place the air bag module in a safe location with the front facing upward.

    8.  
    9. Remove the steering wheel nut.
    10.  
    11. Using a steering wheel puller, press the steering wheel from the steering column.
    12.  

  12.  
  13. Remove the instrument panel by performing the following procedure:
    1. Remove the steering column cover screws and the cover.
    2.  
    3. Remove the hood lock release lever.
    4.  
    5. Remove the No. 1 lower finish panel.
    6.  
    7. Remove the combination switch.
    8.  
    9. Remove the glove compartment door.
    10.  
    11. Remove the No. 2 lower finish panel.
    12.  
    13. Remove the lower center cover.
    14.  
    15. Remove the rear console box.
    16.  
    17. Remove the heater control knobs; then, pry out the center cluster finish panel.
    18.  
    19. Remove the radio and the heater control assembly.
    20.  
    21. Remove the 2 center cluster finish lower panel screws and the panel; then, disconnect the connector.
    22.  
    23. Remove the stereo opening cover.
    24.  
    25. Remove the 5 cluster finish panel screws and the combination meter.
    26.  
    27. Remove the No. 1 register.
    28.  
    29. Remove the heater ducts from the No.1 and No. 2 registers.
    30.  
    31. Remove the glove compartment door reinforcement.
    32.  
    33. Remove the No. 1 and No. 2 brace.
    34.  
    35. Remove the instrument panel electrical connectors.
    36.  
    37. Remove the 2 instrument panel bolts and the instrument panel.
    38.  
    39. Remove the instrument panel reinforcement.
    40.  

  14.  
  15. Remove the evaporator housing by performing the following procedure:
    1. Disconnect the refrigerant lines from the evaporator housing; then, discard the O-rings and plug the openings to prevent contamination.
    2.  
    3. Remove the evaporator-to-chassis grommets.
    4.  
    5. Remove the drain pipe grommet.
    6.  
    7. Disconnect the connectors to the evaporator housing.
    8.  
    9. Remove the 5 evaporator housing-to-chassis screws, the nut and the evaporator housing.
    10.  

  16.  
  17. Disconnect the control cables from the heater housing.
  18.  
  19. Remove the heater housing-to-No. 4 register duct screw and the duct.
  20.  
  21. Remove the heater housing-to-center register duct screw and the duct.
  22.  
  23. Remove the heater housing-to-foot air duct screw and the duct.
  24.  
  25. Remove the 2 heater housing-to-chassis bolts/nut and the heater housing.
  26.  
  27. Remove the 3 heater core-to-heater housing screws, plates and clamp.
  28.  
  29. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. View of the driver-s side air bag module Torx® screws-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and air bag module assembly-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel assembly-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel registers and braces-Toyota T-100



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, heater core, heater housing and evaporator housing assembly-Toyota T-100

  30.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install the 3 heater core-to-heater housing screws, plates and clamp.
  4.  
  5. Install the heater housing and the 2 heater housing-to-chassis bolts/nut.
  6.  
  7. Install the heater housing-to-foot air duct and the duct screw.
  8.  
  9. Install the heater housing-to-center register duct and the duct screw.
  10.  
  11. Install the heater housing-to-No. 4 register duct and the duct screw.
  12.  
  13. Connect the control cables to the heater housing.
  14.  
  15. Install the evaporator housing by performing the following procedure:
    1. Install the evaporator housing, the nut and the 5 evaporator housing-to-chassis screws.
    2.  
    3. Connect the connectors to the evaporator housing.
    4.  
    5. Install the drain pipe grommet.
    6.  
    7. Install the evaporator-to-chassis grommets.
    8.  
    9. Using new O-rings, connect the refrigerant lines to the evaporator housing.
    10.  

  16.  
  17. Install the instrument panel by performing the following procedure:
    1. Install the instrument panel reinforcement.
    2.  
    3. Install the instrument panel and the 2 instrument panel bolts.
    4.  
    5. Install the instrument panel electrical connectors.
    6.  
    7. Install the No. 1 and No. 2 brace.
    8.  
    9. Install the glove compartment door reinforcement.
    10.  
    11. Install the heater ducts to the No.1 and No. 2 registers.
    12.  
    13. Install the No. 1 register.
    14.  
    15. Install the combination meter and the 5 cluster finish panel screws.
    16.  
    17. Install the stereo opening cover.
    18.  
    19. Connect the connector; then, install the center cluster finish lower panel and the 2 panel screws.
    20.  
    21. Install the heater control assembly and the radio.
    22.  
    23. Install the center cluster finish panel and the heater control knobs.
    24.  
    25. Install the rear console box.
    26.  
    27. Install the lower center cover.
    28.  
    29. Install the No. 2 lower finish panel.
    30.  
    31. Install the glove compartment door.
    32.  
    33. Install the combination switch.
    34.  
    35. Install the No. 1 lower finish panel.
    36.  
    37. Install the hood lock release lever.
    38.  
    39. Install the steering column cover and the cover screws.
    40.  

  18.  
  19. Install the steering wheel by performing the following procedure:
    1. Install the steering wheel to the steering column.
    2.  
    3. Install the steering wheel nut and torque it to 26 ft. lbs. (35 Nm).
    4.  
    5. Carefully, install the air bag module and connect the electrical connector.
    6.  
    7. Using a Torx® wrench, tighten the steering wheel screws to 78 inch lbs. (9.0 Nm).
    8.  
    9. At both sides of the steering wheel, install the side covers.
    10.  

  20.  
  21. Install the front pillar garnish, the front door scuff plate and the cowl side trim.
  22.  
  23. Connect the heater hoses to the heater core.
  24.  
  25. Refill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Evacuate and charge the air conditioning system.
    NOTE
    If equipped with a theft-deterrent system, enter the code and reprogram the radio.

  30.  
  31. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  32.  

 
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