Yaris 2007

Removal & Installation

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CAUTION
Some models covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in the Chassis Electrical Section.

  1. Disconnect the negative battery cable.
    CAUTION
    Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.

  2.  
  3. Discharge refrigerant from refrigeration system.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Remove the wiper arm and link assembly.
  8.  
  9. Remove all cowling.
  10.  
  11. Disconnect suction tube sub-assembly:
    1. Remove the bolt.
    2.  
    3. Turn the hook type connector clockwise and disconnect the suction tube.
    4.  
    5. Remove the O-ring from the suction tube.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    6.  

  12.  
  13. Disconnect liquid tube sub-assembly:
    1. Disconnect the liquid tube.
    2.  
    3. Remove the O-ring from liquid tube.
      NOTE
      Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    4.  

  14.  
  15. Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water outlet hose from the heater unit.
  16.  
  17. Using pliers, grip the claws of the clip, slide the clip and disconnect the heater water inlet hose from the heater unit.
  18.  
  19. Remove the instrument panel.
  20.  
  21. Remove the center console.
  22.  
  23. Position front wheels facing straight ahead.
  24.  
  25. Remove the driver-s steering wheel airbag.
  26.  
  27. Remove the steering wheel.
  28.  
  29. Remove the combination switch assembly.
  30.  
  31. Disconnect power steering ECU.
  32.  
  33. Remove instrument panel sub reinforcement.
  34.  
  35. Remove column hole cover silencer sheet.
  36.  
  37. Separate steering sliding yoke sub-assembly.
  38.  
  39. Remove brake pedal (for automatic transaxle).
  40.  
  41. Remove brake master cylinder push rod clevis (for manual transaxle).
  42.  
  43. Remove brake pedal support (for manual transaxle) .
  44.  
  45. Remove steering column assembly.
  46.  
  47. Remove defroster nozzle assembly:
    1. Disconnect the connectors and clamps.
    2.  
    3. Disengage the 5 claws and remove the defroster nozzle.

      Click image to see an enlarged view

      Fig. Remove defroster nozzle assembly

    4.  

  48.  
  49. Remove rear no. 2 air duct (for cold area specification vehicles). Disengage the 4 claws and remove the air duct.
  50.  
  51. Remove rear no. 1 air duct (for cold area specification vehicles). Disengage the 2 claws and remove the air duct.
  52.  
  53. Remove rear no. 3 air duct (for cold area specification vehicles). Disengage the 4 claws and remove the air duct.
  54.  
  55. Remove instrument panel brace sub-assembly:
    1. Disengage the clamp.
    2.  
    3. Remove 2 bolts, screw and nut and remove the instrument panel brace.
    4.  

  56.  
  57. Separate main body ECU:
    1. Disconnect the 5 connectors and 3 clamps.
    2.  
    3. Remove the 2 bolts and separate the main body ECU.
    4.  

  58.  
  59. Separate connector no. 2 holder:
    1. Remove the bolt.
    2.  
    3. Disconnect the connectors and separate the connector No. 2 holder.
    4.  

  60.  
  61. Remove instrument panel reinforcement:
    1. Disconnect the drain hose.
    2.  
    3. Remove the bolt and disconnect the ground wire.
    4.  
    5. Disconnect the connector.
    6.  
    7. Disengage the clamps.
    8.  
    9. Disconnect the connectors and clamps.
    10.  
    11. Remove the 3 bolts and the nut.
    12.  
    13. Remove the 9 bolts and remove the instrument panel reinforcement together with the air conditioning unit.

      Click image to see an enlarged view

      Fig. Disengage the clamps



      Click image to see an enlarged view

      Fig. Disconnect the connectors and clamps



      Click image to see an enlarged view

      Fig. Remove the 3 bolts and the nut.



      Click image to see an enlarged view

      Fig. Remove the 9 bolts and remove the instrument panel reinforcement

    14.  
    15. Disconnect the connector and the 3 clamps.
    16.  
    17. Remove the 3 screws and the air conditioning unit.
    18.  

  62.  
  63. Remove the screw and the air conditioning amplifier.
  64.  
  65. Remove the 3 screws and the air conditioning unit.

    Click image to see an enlarged view

    Fig. A/C unit and related components-1 of 4



    Click image to see an enlarged view

    Fig. A/C unit and related components-2 of 4



    Click image to see an enlarged view

    Fig. A/C unit and related components-3 of 4



    Click image to see an enlarged view

    Fig. A/C unit and related components-4 of 4

  66.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Add engine coolant.
  4.  
  5. Connect cable to negative battery terminal.
  6.  
  7. Check SRS warning light.
  8.  
  9. Charge refrigerant.
  10.  
  11. Warm up engine.
  12.  
  13. Check for engine coolant leakage.
  14.  
  15. Check for refrigerant leak.
  16.  
  17. Position front wheels facing straight ahead.
  18.  

 
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