Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000Z28W
Model Year Start: 2017 Model: Sienna Prod Date Range: [08/2016 -           ]
Title: HEATING / AIR CONDITIONING: FRONT AIR CONDITIONING UNIT: REMOVAL; 2017 - 2020 MY Sienna [08/2016 -        ]

REMOVAL

PROCEDURE

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

2017 - 2020 MY Sienna [08/2016 -        ]; HEATING / AIR CONDITIONING: REFRIGERANT: REPLACEMENT+

2. REMOVE V-BANK COVER SUB-ASSEMBLY

2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE NO. 1 ENGINE UNDER COVER

2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

4. DRAIN ENGINE COOLANT

2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (COOLING): COOLANT: REPLACEMENT+

5. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

2017 - 2020 MY Sienna [08/2016 -        ]; 2GR-FKS (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL

6. DISCONNECT HEATER WATER OUTLET HOSE A

(a) Slide the hose clip to disconnect the heater water outlet hose A.

7. DISCONNECT HEATER WATER INLET HOSE A

(a) Slide the hose clip to disconnect the heater water inlet hose A.

8. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

(a) Remove the bolt.

(b) Turn the hook connector counterclockwise and disconnect the air conditioner tube and accessory assembly.

(c) Remove the 2 O-rings from the air conditioner tube and accessory assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent the entry of moisture and foreign matter.

9. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY

2016 - 2017 MY Sienna [12/2015 - 11/2017]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: REMOVAL 2018 - 2020 MY Sienna [11/2017 -        ]; INTERIOR PANELS / TRIM: INSTRUMENT PANEL SAFETY PAD: REMOVAL

10. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY

(a) Remove the clip.

(b) Disengage the 3 claws to remove the No. 3 air duct sub-assembly.

11. REMOVE STEERING COLUMN ASSEMBLY

2016 - 2020 MY Sienna [12/2015 -        ]; STEERING COLUMN: STEERING COLUMN ASSEMBLY: REMOVAL

12. REMOVE ECU INTEGRATION BOX RH

2016 - 2017 MY Sienna [12/2015 - 11/2017]; THEFT DETERRENT / KEYLESS ENTRY: CERTIFICATION ECU: REMOVAL+ 2018 - 2020 MY Sienna [11/2017 -        ]; THEFT DETERRENT / KEYLESS ENTRY: CERTIFICATION ECU: REMOVAL+

13. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

2016 - 2020 MY Sienna [12/2015 -        ]; HEATING / AIR CONDITIONING: AIR CONDITIONING AMPLIFIER: REMOVAL+

14. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

2016 - 2020 MY Sienna [12/2015 -        ]; POWER DISTRIBUTION: MAIN BODY ECU: REMOVAL+

15. REMOVE CENTER AIRBAG SENSOR ASSEMBLY

2016 - 2020 MY Sienna [12/2015 -        ]; SUPPLEMENTAL RESTRAINT SYSTEMS: CENTER AIRBAG SENSOR ASSEMBLY: REMOVAL+

16. DISCONNECT FRONT DOOR WIRE LH

(a) Disconnect the 3 connectors.

17. DISCONNECT FRONT DOOR WIRE RH

(a) Disconnect the 3 connectors.

18. REMOVE FRONT DOOR PANEL SUB-ASSEMBLY LH

(a) Remove the bolt from the front door check.

(b) Remove the 2 bolts from the front door upper hinge.

(c) Remove the 2 bolts from the front door lower hinge, and then remove the front door panel sub-assembly LH from the vehicle.

NOTICE:

Be careful not to cut, break, or damage the front door wire.

19. REMOVE FRONT DOOR PANEL SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

20. REMOVE FRONT FLOOR CARPET ASSEMBLY

2016 - 2020 MY Sienna [12/2015 -        ]; THEFT DETERRENT / KEYLESS ENTRY: ELECTRICAL KEY OSCILLATOR(for Rear Floor): REMOVAL

21. REMOVE REAR NO. 2 AIR DUCT

(a) Remove the clip.

(b) Disengage the 2 claws to remove the rear No. 2 air duct.

22. REMOVE REAR NO. 4 AIR DUCT

HINT:

Use the same procedure as for the No. 2 air duct.

23. REMOVE NO. 5 INSTRUMENT PANEL BRACKET

(a) Disconnect the 3 connectors.

HINT:

If the vehicle is equipped with USB audio system, disconnect the connectors.

(b) Remove the 3 nuts and No. 5 instrument panel bracket.

24. REMOVE TELEVISION BRACKET

(a) Remove the 4 bolts and television bracket.

25. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Disconnect the connector.

(b) Disengage the 5 clamps.

(c) Remove the bolt to disconnect the ground wire.

(d) Remove the 2 bolts, 2 nuts and screw to remove the No. 1 instrument panel brace sub-assembly.

26. REMOVE NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Disconnect the connector.

(b) Disengage the 5 clamps.

(c) Remove the bolt to disconnect the ground wire.

(d) Remove the bolt, 2 nuts and screw to remove the No. 2 instrument panel brace sub-assembly.

27. SEPARATE NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Remove the 3 nuts to separate the No. 1 air duct sub-assembly.

28. SEPARATE INSTRUMENT PANEL WIRE

(a) Disconnect the connectors.

(b) Remove the bolt to disconnect the ground wire.

(c) Disengage the clamps to disconnect the instrument panel wire.

29. REMOVE INSTRUMENT PANEL REINFORCEMENT

(a) Remove the 3 bolts and nut.

(b) Remove the 3 caps.

(c) Remove the 2 caps.

(d) Remove the 5 bolts as shown in the illustration.

*1

Movable Collar

*2

Body

*3

Instrument Panel Reinforcement

-

-

*a

Step 1

*b

Step 2

*c

Step 3

*d

Step 4

(e) Remove the instrument panel reinforcement with air conditioning unit assembly.

30. REMOVE AIR CONDITIONING UNIT

(a) Remove the 3 screws and air conditioning unit.