AIR CONDITIONING SYSTEM

AIR CONDITIONING SYSTEM PRECAUTION CAUTION: AIR CONDITIONING SYSTEM Because the compressor has a highvoltage circuit, wear insulated gloves and pull out the service plug to cut the highvoltage circuit before inspection. 551 551AE01 1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION AC2810 AC2811 3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. (b) apply clean petroleum jelly to the skin. (c) go immediately to a hospital or see a physician for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT Wrong LO HI Okay LO HI N11084 6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure valves are opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc. 2004 Prius Preliminary Release (RM1075U) 740

552 AIR CONDITIONING SYSTEM 9. NOTICE FOR INITIALIZATION: (a) When disconnecting the negative () battery terminal, initialize the following systems after the terminal is reconnected. System Name see page Power Window Control System 0128 10. NOTICES FOR HYBRID SYSTEM ACTIVATION: When the warning lamp is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. With the power switch s power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. 11. PRECAUTIONS TO BE OBSERVED WHILE SERVIC- ING For the electric inverter compressor, use the ND OIL11. Electrical insulation performance may decrease significantly if even a small amount of oil other than ND OIL11 is used (or enters) in the refrigeration cycle, causing the DTC to be output. If other oil is accidentally used and a DTC is output, collect the compressor oil in the compressor and replace it with NDOIL11 to increase the NDOIL11 ratio amount. Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than NDOIL11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing the DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug clip before inspection, as some of the procedures require disconnecting the highvoltage connectors (see page 051339). 2004 Prius Preliminary Release (RM1075U) 741

AIR CONDITIONING SYSTEM 553 LOCATION 551AF01 Engine Room J/B PTC Heater Relay No.1 PTC Heater Relay No.2 Electric Inverter Compressor (w/motor Compressor Assy) Pressure Switch Heater Water Pump Assy Integration Relay Fusible Link Block Assy (HTR 40 A) A/C Ambient Temperature Sensor A/C Inverter (w/converter Inverter Assy) Engine Room J/B Integration Relay Fusible Link Block Assy (HTR 40 A) PTC HTR1 Fuse (30 A) *1 PTC HTR2 Fuse (30 A) *1 *1: Cold Area Models I36307 2004 Prius Preliminary Release (RM1075U) 742

554 AIR CONDITIONING SYSTEM Spiral Cable Steering Pad Switch RH Gateway ECU Steering Pad Switch LH Combination Meter Multi Display A/C Solar Sensor Hybrid Vehicle Control ECU Driver Side J/B Heater Relay A/C Fuse (10 A) GAUGE Fuse (10 A) ECUB Fuse (15 A) Body ECU DLC3 ECM A/C Room Temperature Sensor (Built in A/C Room Humidity Sensor) A/C Control Assembly I36308 2004 Prius Preliminary Release (RM1075U) 743

AIR CONDITIONING SYSTEM 555 Cooler Expansion Valve A/C Evaporator Temperature Sensor Cooler Evaporator No.1 Air Inlet Control Servomotor Air Outlet Control Servomotor Blower Assy PTC Heater *1 Heater Radiator Unit Assy Blower w/ Fan Motor Subassy Air Conditioning Radiator Assy Air Mix Control Servomotor *1: Cold Area Models I36310 2004 Prius Preliminary Release (RM1075U) 744

556 REFRIGERANT REFRIGERANT ONVEHICLE INSPECTION 5519C01 Sight Glass 1. INSPECT REFRIGERANT VOLUME (a) Check the sight glass of the cooler unit refrigerant liquid pipe E. (1) Set the vehicle according to the conditions below. Item All Doors Temperature setting Blower Speed A/C Condition Fully open MAX COLD HI ON (2) Check the sight glass under these conditions. I38559 Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* 2 No bubbles exist (DTC 76 is output) Empty, insufficient or excessive Refer to 3 and 4 3 4 5 6 No temperature difference between compressor inlet and outlet Considerable temperature difference between compressor inlet and outlet Immediately after air conditioning is turned off, refrigerant remains clear Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Empty or nearly empty Proper or excessive Refer to 5 and 6 Excessive (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear (1) Discharge refrigerant (2) Remove air and supply proper amount of purified refrigerant Proper *: Bubbles in the sight glass with room temperature higher than usual can be considered normal if cooling is sufficient. 2004 Prius Preliminary Release (RM1075U) 745

REFRIGERANT 557 2. INSPECT REFRIGERANT PRESSURE WITH MAN- IFOLD GAUGE SET (a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Test conditions: Temperature at the air inlet with the switch set at RECIRC is 30 to 35 C (86 to 95 F) Blower speed control switch at HI position Temperature control switch at MAX COOLD position A/C switch ON Fully open doors (1) The refrigeration system functions normally Gauge reading: Low pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm 2 ) High pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm 2) (2) Moisture present in refrigeration system E50573 Condition: Periodically cools and then fails to cool I22117 Symptom Probable cause Diagnosis Corrective Actions During operation, pressure on low pressure side cycles between normal and vacuum Moisture in refrigerating system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. Cooler dryer in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant (1) Replace cooler dryer (2) Remove moisture in cycle by repeatedly evacuating air (3) Supply proper amount of new refrigerant 2004 Prius Preliminary Release (RM1075U) 746

558 REFRIGERANT Condition: Cooling system does not function effectively. (3) Insufficient cooling I22118 Symptom Probable cause Diagnosis Corrective Actions (1) Check for gas leakage and repair if necessary Pressure is low on both low and (2) Supply proper amount of new high pressure sides Bubbles are continuously seen through sight glass Gas leakage in refrigeration system Insufficient refrigerant Refrigerant leaking refrigerant (3) If the indicated pressure value is close to 0 when connected to Insufficient cooling performance the gauge, create a vacuum after inspecting and repairing location of leakage Condition: Cooling system does not function effectively. (4) Poor circulation of refrigerant I22119 Symptom Probable cause Diagnosis Corrective Action Pressure is low on both low and high pressure sides Frost exists on pipe from cooler Refrigerant flow is obstructed by dirt in cooler condenser core Cooler condenser core is clogged Replace cooler condenser core condenser to A/C unit 2004 Prius Preliminary Release (RM1075U) 747

559 REFRIGERANT (5) Refrigerant does not circulate Condition: Cooling system does not function (sometimes it may function). I22120 Symptom Probable cause Diagnosis Corrective Actions (1) Check cooler expansion valve Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side Frost or condensation is seen on piping on both sides of cooler condenser core or expansion valve Refrigerant flow is obstructed by moisture or dirt in refrigeration system Refrigerant flow obstructed by gas leaked from cooler expansion valve Refrigerant does not circulate (2) Clean out dirt in cooler expansion valve by blowing air (3) Replace cooler condenser core (4) Evacuate and charge new refrigerant (5) For gas leakage from cooler expansion valve, replace cooler expansion valve Condition: Cooling system does not function effectively. (6) Refrigerant overcharged or insufficient cooling of condenser I22121 Symptom Probable cause Diagnosis Correcyive Actions (1) Clean cooler condenser core Pressure is too high on both low Excessive refrigerant in fin and high pressure sides Excessive refrigerant cycle excessive refrigerant is (2) Check cooling fan with con- No air bubbles are seen through Insufficient cooling of cooler con- supplied denser fan motor operation the sight glass when compressor denser core Insufficienr cooling of cooler con- (3) If (1) and (2) are normal, check speed decreases denser core amount of refrigerant and supply proper amount of refrigerant 2004 Prius Preliminary Release (RM1075U) 748

5510 REFRIGERANT (7) Air present in refrigeration system Condition: Cooling system does not function. NOTE : These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. I22122 Symptom Probable cause Diagnosis Corrective Actions Pressure is too high on both low and high pressure sides Low pressure piping is too hot to touch Bubbles are seen through sight Air in system Air present in refrigeration system Insufficient vacuum purging (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate and charge new refrigerant glass (8) Expansion valve malfunction Condition: Insufficient cooling I22123 Symptom Probable cause Diagnosis Corrective Action Pressure is too high on both low and high pressure sides Frost or large amount of condensation on piping on low pressure side Trouble in cooler expansion valve Excessive refrigerant in low pressure piping Cooler expansion valve is opened too wide Replace cooler expansion valve 2004 Prius Preliminary Release (RM1075U) 749

REFRIGERANT 5511 (9) Defective compression compressor Condition: Insufficient cooling I22124 Symptom Probable cause Diagnosis Corrective Action Pressure is too high on both low and high pressure sides Pressure is too low on high pressure side Internal leak in cooler compressor Compression failure Leakage from damaged valve or sliding parts are broken Repair or replace cooler compressor Gauge readings (Reference) Pressure on low pressure side MPa (kgf/cm 2 ) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.9) 0.3 (3.0) 0.2 (2.0) 0.27 (2.85) 0.22 (2.25) 0.2 (2.1) 0.14 (1.5) 1.2 (12.3) 1.25 (12.8) 1.32 (13.5) Blower LO Zone 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) Pressure on high pressure side MPa (kgf/cm 2 ) I30081 2004 Prius Preliminary Release (RM1075U) 750

5512 REPLACEMENT REFRIGERANT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (a) Turn the A/C switch on. (b) Operate the A/C with the setting temperature at 25 C (77 F) and the blower level at LO for 10 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. (c) Stop the engine. (d) Using SST, let the refrigerant gas out. SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) 2. CHARGE REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC134a (R134a). Standard: 450 30 g (15.9 1.1 oz.) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) 5519D01 Amount to be charged Charge 100 g (3.53 oz.) Mean value in proper range High Pressure 30 g ( 1.1 oz.) Point where bubbles disappear Overcharged Subcool system Refrigerant Amount I30082 Do not turn the A/C on before charging with refrigerant as the cooler compressor doesn t work properly without any refrigerant, which causes the compressor to overheat. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass. HINT: Prepare a service can to recharge the refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90 %. 3. WARM UP COMPRESSOR (a) Turn the A/C switch on continuously for at least 1 minute to warm up the compressor. Be sure to warm up compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor. 2004 Prius Preliminary Release (RM1075U) 751

REFRIGERANT 5513 4. INSPECT LEAKAGE OF REFRIGERANT (a) After recharging the refrigerant gas, inspect leakage of refrigerant gas using a halogen leak detector. (b) Perform in these conditions: Power switch off. Secure good ventilation (the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas). Repeat the test 2 or 3 times. Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is off: approx. 392 to 588 kpa (4 to 6 kgf/cm 2, 57 to 85 psi) Drain Hose Gas Leak Detector N14519 (c) Bring the gas leak detector close to the drain hose with the detector s power off. HINT: After the blower motor has stopped, leave the cooling unit for more than 15 minutes. Expose the gas leak detector sensor under the drain hose. When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (d) If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. (e) Disconnect the connector and leave the pressure switch for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. 2004 Prius Preliminary Release (RM1075U) 752

5514 REFRIGERANT LINE REFRIGERANT LINE COMPONENTS 5519E01 Cooler Refrigerant Liquid Pipe E (To Cooler Unit) Piping Clamp (Quick Joint) Suction Hose Subassy Discharge Hose Subassy 5.4 (55, 49 in. lbf) 9.8 (100, 87 in. lbf) 9.8 (100, 87 in. lbf) Electric Inverter Compressor Assy Condenser assy (w/ Receiver) (w/ Receiver Condenser Assy) I38552 N m (kgf cm, ft lbf) : Specified torque I39642 2004 Prius Preliminary Release (RM1075U) 753

AIR CONDITIONING RADIATOR ASSY COMPONENTS AIR CONDITIONING RADIATOR ASSY 5515 5519F01 Defroster Nozzle Assy Side Defroster Nozzle Duct No.1 Heater to Register Duct No.3 Side Defroster Nozzle Duct No.3 Heater To Register Duct No.2 Heater to Register Duct No.1 Piping Clamp (Quick Joint) Suction Hose Subassy Cooler Refrigerant Liquid Pipe E (To Cooler Unit) Piping Clamp(Quick Joint) Oring Oring Instrument Panel Brace Subassy No.1 Air Conditioning Unit Assy Blower Assy Compressor Oil NDOIL 11 or equivalent Nonreusable part : Use repair screws (parts No.9015970003) if the screws removed before cannot be tightened. Air Duct Rear No.3 I38836 2004 Prius Preliminary Release (RM1075U) 754

5516 AIR CONDITIONING RADIATOR ASSY Piping Clamp Piping Clamp Defroster Nozzle Assy LWR Heater Radiator Unit Subassy Air Conditioning Tube & Accessory Assy Expansion Valve Cover Cooler Evaporator Subassy No.1 Cooler Expansion Valve Oring Air Outlet Damper Servomotor Oring 3.5 (35, 30 in. lbf) Air Mix Control Servomotor Heater Piping Cover Evaporator Temperature Sensor (Cooler Thermistor No.1) Aspirator Pipe Quick Heater Assy Air Conditioning Amplifier Assy Air Duct No.1 N m (kgf cm, ft lbf) : Specified torque Compressor Oil NDOIL 11 or equivalent Nonreusable part I38837 2004 Prius Preliminary Release (RM1075U) 755

OVERHAUL AIR CONDITIONING RADIATOR ASSY 5517 HINT: Installation is in the reverse order of removal. COMPONENTS for instrument panel safety pad: See page 711. COMPONENTS for air conditioner radiator assy: See page 5515. 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 5512) SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) 5519G01 2. DISCONNECT SUCTION HOSE SUBASSY (a) Check the SST installation direction. SST 0987000015 HINT: Set the SST so that the stopper side is on the piping clamp lock side. (b) Install the SST on the piping clamp. I03838 Push SST Release Lever Pull I03839 (c) Push down on the SST with your thumb while holding the pipe with both hands. Be careful not to bend the pipe. (d) Pull the SST until the stopper touches the pipe. (e) Raise the SST stopper and remove the piping clamp with the SST from the pipe. (f) Remove the piping clamp from the SST. Disconnect the tube using hand Screw Driver (g) Disconnect the suction hose. (h) Remove the 2 Orings from the suction hose. Do not apply excessive force to the suction hose. Seal the opening of the disconnected part using vinyl tape to prevent moisture and foreign matter from entering. I06919 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) SST 0987000025 HINT: Disconnect the cooler refrigerant liquid pipe E following the same procedures as for the suction hose. 2004 Prius Preliminary Release (RM1075U) 756

5518 AIR CONDITIONING RADIATOR ASSY 4. DISCONNECT HEATER WATER HOSE B Heater Water Hose B (a) Slide the clip and disconnect the heater water hose B. Heater Water Hose A Do not apply excessive force to the water hose B. Prepare a drain pan or cloth for when the cooling water leaks. 5. DISCONNECT HEATER WATER HOSE A (a) Slide the clip and disconnect the heater water hose A. I38565 Do not apply excessive force to the water hose A. Prepare a drain pan or cloth for when the cooling water leaks. 6. REMOVE INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) HINT: Refer to the removal procedures for the instrument panel with the passenger airbag assy. 7. REMOVE INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) HINT: Refer to the removal procedures for the instrument panel lower. 8. REMOVE AIR DUCT REAR NO.3 (a) Fold back the floor carpet. HINT: Fold back the floor carpet so that the air duct rear No.3 can be removed. (b) Disengage the 10 claws and then remove the air duct rear No.3. 10 Claws I38823 9. REMOVE HEATER TO REGISTER DUCT NO.3 (a) Remove the clip and then the heater to register duct No.3 with the side defroster nozzle duct No.2. I38566 10. REMOVE HEATER TO REGISTER DUCT NO.1 (a) Remove the heater to register duct No.1 with the side defroster nozzle duct No.1. I38567 2004 Prius Preliminary Release (RM1075U) 757

AIR CONDITIONING RADIATOR ASSY 5519 11. REMOVE HEATER TO REGISTER DUCT NO.2 (a) Remove the heater to register duct No.2. I38568 12. REMOVE DEFROSTER NOZZLE ASSY (a) Remove the 2 clips. (b) Disengage the 3 claws and then remove the defroster nozzle assy. 3 Claws I38569 13. REMOVE TRANSMISSION CONTROL ECU ASSY 14. REMOVE ECM (SEE PAGE 1024) 15. REMOVE NETWORK GATEWAY ECU (SEE PAGE 6726) 16. REMOVE INSTRUMENT PANEL BRACE SUBASSY NO.1 (a) Remove the clamp and disconnect the harness. (b) Remove the 2 bolts and the nut and then the instrument panel brace subassy No.1. I39536 17. REMOVE AIR CONDITIONING AMPLIFIER ASSY (SEE PAGE 5547) 18. REMOVE STEERING COLUMN ASSY (SEE PAGE 508) 2004 Prius Preliminary Release (RM1075U) 758

5520 AIR CONDITIONING RADIATOR ASSY 19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY (a) Disconnect each connector and remove each clamp. Disconnect the wire harness. 7 Clamps I38978 (b) Remove the 7 bolts and the 2 nuts and then the instrument panel reinforcement assy with the air conditioner unit assy. I38973 2004 Prius Preliminary Release (RM1075U) 759

AIR CONDITIONING RADIATOR ASSY 5521 20. REMOVE AIR CONDITIONER UNIT ASSY (a) Disconnect the 5 connectors and remove the 9 clamps. Disconnect the wire harness. 9 Clamps I38974 (b) Remove the bolt and the clamp and then disconnect the junction connector. Clamp I38975 (c) Remove the 2 screws and the air conditioner unit assy from the instrument panel reinforcement assy. I38976 21. REMOVE BLOWER ASSY (a) Remove the 2 screws. (b) Disengage the fittings with the air conditioner assy and then remove the blower assy. I38977 2004 Prius Preliminary Release (RM1075U) 760

5522 AIR CONDITIONING RADIATOR ASSY 22. REMOVE DEFROSTER NOZZLE ASSY LWR (a) Disengage the 2 claws and then remove the defroster lower nozzle assy. 2 Claws I38835 23. REMOVE AIR MIX CONTROL SERVOMOTER (a) Remove the 2 screws and then the airmix control servomotor. I38834 24. AIR OUTLET CONTROL SERVOMOTER (a) Remove the 2 screws and disengage the claw. (b) Remove the air outlet control servomoter. Claw I38825 25. REMOVE AIR CONDITIONING TUBE & ACCESSORY ASSY (a) Remove the 2 screws and then the expansion valve cover. I38826 (b) Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts. (c) Remove the air conditioner tube assy. (d) Remove the 2 Orings from the air conditioner tube assy. I38827 2004 Prius Preliminary Release (RM1075U) 761

AIR CONDITIONING RADIATOR ASSY 5523 26. REMOVE COOLER EXPANSION VALVE (a) Remove the cooler expansion valve from the cooler evaporator No.1. I38828 27. REMOVE HEATER RADIATOR UNIT SUBASSY (a) Remove the clamp and then disconnect the evaporator temperature sensor connector. (b) Remove the clamp and disengage the 2 claws. Remove the heater piping cover. 2 Clamps 2 Claws I39537 (c) Remove the 4 screws and the 4 clamps. (d) Remove the radiator heater unit from the air conditioner radiator assy. Prepare a drain pan or cloth for when the cooling water leaks. I38830 28. REMOVE AIR DUCT NO.1 (a) Remove the 2 screws and then the air duct No.1. E70849 I39539 2004 Prius Preliminary Release (RM1075U) 762

5524 AIR CONDITIONING RADIATOR ASSY 29. REMOVE QUICK HEATER ASSY (a) Remove the 4 screws and then the quick heater assy. I38833 30. REMOVE COOLER EVAPORATOR SUBASSY NO.1 (a) Remove the 7 screws and then the cooler evaporator No.1 from the heater case. I38832 (b) Remove the 2 Orings from the cooler evaporator No.1. E69079 31. REMOVE EVAPORATOR TEMPERAURE SENSOR (a) Disengage the 2 claws and then remove the evaporator temperature sensor. : 2 Claws I38987 32. INSTALL COOLER EVAPORATOR SUBASSY NO.1 (a) Sufficiently apply compressor oil (NDOIL11) to 2 new O rings and fitting surface. Install the 2 Orings to the cooler evaporator No.1. Compressor oil: NDOIL 11 or equivalent E69079 2004 Prius Preliminary Release (RM1075U) 763

AIR CONDITIONING RADIATOR ASSY 5525 Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the cooler evaporator No.1 with the 7 screws. I38832 33. INSTALL COOLER EXPANSION VALVE (a) Install the cooler expansion valve to the cooler evaporator No.1. I38828 I38827 34. INSTALL AIR CONDITIONING TUBE & ACCESSORY ASSY (a) Sufficiently apply compressor oil (NDOIL11) to 2 new O rings and fitting surface. Install the 2 Orings to the conditioner tube assy. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the air conditioner tube assy to the cooler evaporator No.1, placing the cooler expansion valve between them, Using a hexagon wrench 4 mm (0.16 in.), install the 2 hexagon bolts. Torque: 3.5 N m (35 kgf cm, 30 in. lbf) 2004 Prius Preliminary Release (RM1075U) 764

5526 AIR CONDITIONING RADIATOR ASSY (c) Install the expansion cover with the 2 screws. I38826 35. INSTALL AIR CONDITIONER UNIT ASSY (a) Install the air conditioner unit assy to the instrumentpanel reinforcement assy with the 2 screws. HINT: Use repair screws (parts No. 9015970003) if the screws removed before cannot be tightened. I38976 (b) Connect the junction connector with the bolt and the clamp. Clamp I38975 (c) Install the instrument panel wire harness with the 5 connectors and the 9 clamps. 9 Clamps I38974 2004 Prius Preliminary Release (RM1075U) 765

AIR CONDITIONING RADIATOR ASSY 5527 36. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY (a) Install the instrument panel reinforcement assy with the 7 bolts. (b) Install the 2 nuts to the air conditioner unit assy and temporarily tighten them. I38973 37. INSTALL INSTRUMENT PANEL BRACE SUBASSY NO.1 (a) Install the instrument panel brace subassy No.1 with the 2 bolts and nut. (b) Install the harness with a clamp. I39536 38. FULLY TIGHTEN AIR CONDITIONER UNIT ASSY (a) Fully tighten the air conditioner unit assy with the 2 nuts. Tighten the nuts in the order indicated in the illustration. (1) (2) I40423 39. INSTALL STEERING COLUMN ASSY (SEE PAGE 508) 40. INSTALL INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) HINT: Refer to the installation procedures for the instrument panel subassy lower. 41. INSTALL INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assy. 2004 Prius Preliminary Release (RM1075U) 766

5528 AIR CONDITIONING RADIATOR ASSY 42. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) Connect Wrong Gap (a) Remove the attached vinyl tape from the pipe disconnected part. (b) Sufficiently apply compressor oil (NDOIL11) to 2 new O rings and pipe connecting part. Do not use any compressor oil other than NDOIL11 I06878 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (c) Install the Orings to the pipe. (d) Insert the pipe joint into the cooler unit fitting hole securely. (e) Using the piping clamp, install the cooler unit refrigerant liquid pipe E. Ensure that the piping clamp is securely engaged. 43. INSTALL SUCTION HOSE SUBASSY HINT: Install the suction hose subassy following the same procedures as for the cooler unit refrigerant liquid pipe E. 44. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 45. ADD ENGINE COOLANT (SEE PAGE 1611) 46. CHARGE REFRIGERANT (SEE PAGE 5512) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) Specified amount: 450 30 g (15.87 1.05 oz.) 47. CHECK FOR ENGINE COOLANT LEAKS (SEE PAGE 1611) 48. WARM UP COMPRESSOR (SEE PAGE 5512) 49. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 50. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT (SEE PAGE 051211) 2004 Prius Preliminary Release (RM1075U) 767

BLOWER ASSY 5529 BLOWER ASSY COMPONENTS 5519H01 Blower Assy Air Duct Subassy Air Inlet Servomotor Clean Air Filter Blower Motor Control Blower w/ Fan Motor Subassy Air Filter Cover Plate Cooler Wiring Harness Subassy No.2 Blower Motor Cover : Use repair screw (parts No.9015970003) if the screw removed before cannot be tightened. I38849 2004 Prius Preliminary Release (RM1075U) 768

5530 OVERHAUL BLOWER ASSY HINT: Installation is in the reverse order of removal. COMPONENTS for instrument panel safety pad: See page 711. COMPONENTS for blower assy: See page 5529. 1. REMOVE INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) 2. REMOVE INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) 3. REMOVE TRANSMISSION CONTROL ECU ASSY 4. REMOVE ECM (SEE PAGE 1024) 5. REMOVE NETWORK GATEWAY ECU (SEE PAGE 6726) 6. REMOVE HEATER TO REGISTER DUCT NO.1 (SEE PAGE 5517) 5519I01 7. REMOVE AIR DUCT SUBASSY (a) Remove the 2 screws and then the air duct subassy. I40426 8. REMOVE BLOWER ASSY (a) Disconnect the 10 connectors and remove the 5 clamps. (b) Disconnect the wire harness. 5 Clamps I38839 2004 Prius Preliminary Release (RM1075U) 769

BLOWER ASSY 5531 (c) Remove the 3 screws the nut and then the blower assy. I38841 9. REMOVE AIR INLET SERVOMOTER (a) Remove the 3 screws and then the air inlet servomoter. I38843 10. REMOVE BLOWER MOTOR CONTROL (a) Disconnect the connector and remove the 2 screws. (b) Remove the blower motor control. I38844 11. REMOVE COOLER WIRING HARNESS SUBASSY NO.2 (a) Remove the 5 screws and then the blower motor cover. I38845 (b) Remove the cooler wiring harness subassy No.2 from the blower w/fan motor subassy. I38847 2004 Prius Preliminary Release (RM1075U) 770

5532 BLOWER ASSY 12. REMOVE BLOWER W/FAN MOTOR SUBASSY (a) Remove the 3 screws and then the blower w/fan motor subassy. I38846 13. REMOVE CLEAN AIR FILTER (a) Disengage the 2 claws and then remove the air filter cover plate with the clean air filter. (b) Remove the clean air filter from the air filter cover plate. 2 Claws I38848 14. INSTALL BLOWER ASSY (a) Install the blower assy with the 3 screws HINT: Use repair screw (parts No.9015970003) if the screw (A) removed before cannot be tightened. (A) I38841 (b) Install the wire harness with the 10 connectors and 5 clamps. (c) Install the transponder key computer assy connector. 5 Clamps I38839 15. INSTALL INSTRUMENT PANEL SUBASSY LOWER (SEE PAGE 7113) HINT: Refer to the installation procedures for the instrument panel subassy lower. 2004 Prius Preliminary Release (RM1075U) 771

BLOWER ASSY 5533 16. INSTALL INSTRUMENT PANEL SUBASSY W/PASSENGER AIRBAG ASSY (SEE PAGE 717) HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assy. 2004 Prius Preliminary Release (RM1075U) 772

5534 ELECTRIC INVERTER COMPRESSOR ASSY ELECTRIC INVERTER COMPRESSOR ASSY REPLACEMENT 1. REMOVE REAR FLOOR BOARD NO.2(SEE PAGE 21116) 2. REMOVE DECK FLOOR BOX REAR(SEE PAGE 21116) 3. REMOVE REAR FLOOR BOARD NO.3(SEE PAGE 21116) 4. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE601) 5. REMOVE SERVICE PLUG GRIP(SEE PAGE 21116) 6. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) 5519J01 I38560 7. DISCONNECT DISCHARGE HOSE SUBASSY (a) Remove the bolt and disconnect the discharge hose sub assy. (b) Remove the Oring from the discharge hose subassy. Seal the openings of the disconnected parts of the discharge hose and the compressor assy with the electric inverter compressor assy using vinyl tape to prevent moisture and foreign matter from entering. I38561 8. DISCONNECT SUCTION HOSE SUBASSY (a) Remove the bolt and disconnect the suction hose sub assy. (b) Remove the Oring from the suction hose subaasy. Seal the openings of the disconnected parts of the suction hose and the compressor assy with the electric inverter compressor assy using vinyl tape to prevent moisture and foreign matter from entering. (1) (2) 9. REMOVE ELECTRIC INVERTER COMPRESSOR ASSY (a) Release the greencolored lock.(1) (b) Disconnect the connector.(2) (c) Remove the 3 clamps and disconnect the wire harness. Wear insulated gloves when performing the procedures. Insulate the connector by sealing it with tape. :3 Clamps I38562 2004 Prius Preliminary Release (RM1075U) 773

ELECTRIC INVERTER COMPRESSOR ASSY 5535 (d) Remove the 3 bolts and then the electric inverter compressor assy. I38563 Service Valve Service Valve I39541 10. INSPECT COMPRESSOR OIL (a) Gradually discharge inert gas (helium) from the service valve when replacing the electric inverter compressor assy with the inverter compressor assy with a new one. Drain the following amount of oil from the new electric inverter compressor before installation. Standard: (Oil capacity inside new electric inverter compressor 100 (+ 15 ml)) (Remaining oil amount in the removed compressor assy with the motor (w/ motor compressor assy)) = (Oil amount to be removed before installation) Observe the precautions on the cooler removal/ installation procedures when checking the amount of compressor oil. Because compressor oil remains in the pipes of the vehicle, if a new cooler compressor assy is installed without removing the oil inside, the amount of oil becomes too great, preventing heat exchange in the refrigerant cycles and causing refrigerant failure and/or abnormal vibration. Check for oil leakage if the remaining oil amount in the removed compressor is too low. If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (1) (2) 11. TEMPORARILY TIGHTEN ELECTRIC INVERTER COMPRESSOR ASSY (a) Temporarily tighten the electric inverter compressor assy with the 2 bolts. Tighten them in the order indicated in the illustration. E72576 2004 Prius Preliminary Release (RM1075U) 774

5536 ELECTRIC INVERTER COMPRESSOR ASSY (1) 12. FULLY TIGHTEN ELECTRIC INVERTER COMPRESSOR ASSY (a) Fully tighten the electric inverter compressor assy with the 2 bolts. Torque: 25 N m (255 kgf cm, 18 ft lbf) Tighten them in the order indicated in the illustration. I38564 (2) I41159 (b) Fully tighten the electric inverter compressor assy with the bolt. Torque: 25 N m (255 kgf cm, 18 ft lbf) I38564 I41160 (2) (1) (c) Connect the wire harness. Wear insulated gloves when performing the procedures. (1) Connect the wire harness 3 clamps. (2) Connect the connector.(1) (3) Lock the greencolored lock.(2) I38562 3 Clamps I41121 I38561 13. INSTALL SUCTION HOSE SUBASSY (a) Sufficiently apply compressor oil to a new Oring and fitting surface of the electric inverter compressor assy. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the Oring to the suction hose subassy. (c) Install the suction hose subassy with the bolt. Torque: 9.8 N m (100 kgf cm, 87 in. lbf) 2004 Prius Preliminary Release (RM1075U) 775

ELECTRIC INVERTER COMPRESSOR ASSY 5537 14. INSTALL DISCHARGE HOSE SUBASSY (a) Sufficiently apply compressor oil to a new Oring and fitting surface of the electric inverter compressor assy. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, I38560 compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the Oring to the discharge hose. (c) Install the discharge hose with the bolt. Torque: 9.8 N m (100 kgf cm, 87 in. lbf) 15. INSTALL SERVICE PLUG GRIP(SEE PAGE 21116) 16. CONNECT BATTERY NEGATIVE TERMINAL 17. INSTALL REAR FLOOR BOARD NO.3 18. INSTALL DECK FLOOR BOX REAR 19. INSTALL REAR FLOOR BOARD NO.2 20. CHARGE REFRIGERANT (SEE PAGE 5512) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) Specified amount: 450 30 g (15.87 1.05 oz.) 21. WARM UP COMPRESSOR (SEE PAGE 5512) 22. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 2004 Prius Preliminary Release (RM1075U) 776

5538 W/RECEIVER CONDENSER ASSY ONVEHICLE INSPECTION W/RECEIVER CONDENSER ASSY 1. INSPECT COOLER CONDENSER CORE (a) If the fins of the condenser assy (w/ receiver) are dirty, clean them with water and dry them with compressed air. Do not damage the fins of the cooler condenser core. (b) If the fins of the condenser assy (w/ receiver) are bent, straighten them using a screwdriver or pliers. 2. INSPECT LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check the pipe joints for gas leakage. (b) Check the tightening torque of the joint if gas leakage is detected in a pipe joint. 5519K01 2004 Prius Preliminary Release (RM1075U) 777

W/RECEIVER CONDENSER ASSY 5539 COMPONENTS 5519L01 Inverter Bracket No.1 Radiator Support Upper Suction Bracket 7.5 (76, 66 in. lbf) Hood Lock Assy 5.0 (51, 44 in. lbf) 5.0 (51, 44 in. lbf) Radiator Support Subassy Upper LH 7.5 (76, 66 in. lbf) Radiator Support Subassy Upper RH Angle Discharge Hose Subassy 5.4 (55, 49 in. lbf) 3.9 (40, 35 in. lbf) 3.9 (40, 35 in. lbf) Angle Condenser Assy (w/ Receiver) (w/ Receiver Condenser Assy) 3.9 (40, 35 in. lbf) Cooler Refrigerant Liquid Pipe E (To Cooler Unit) 3.9 (40, 35 in. lbf) 5.4 (55, 49 in. lbf) Cooler Dryer Oring Cap 2.9 (30, 25 in.lbf) Compressor Oil NDOIL 11 or equivalent Nonreusable part N m (kgf cm, ft lbf) : Specified torque I38553 2004 Prius Preliminary Release (RM1075U) 778

5540 W/RECEIVER CONDENSER ASSY 5519M01 OVERHAUL HINT: COMPONENTS for condenser assy: See page 5539. 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 5512) SST 0711058060 (0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) 2. REMOVE FRONT FENDER LINER LH 3. REMOVE FRONT FENDER LINER RH 4. REMOVE FRONT BUMPER COVER 5. REMOVE INVERTER BRACKET NO.1 (SEE PAGE 1633) I38554 6. DISCONNECT DISCHARGE HOSE SUBASSY (a) Remove the bolt and disconnect the discharge hose sub assy from the condenser assy (w/ receiver). (b) Remove the Oring from the discharge hose subassy. Seal the openings of the disconnected parts of the discharge hose and the condenser assy using vinyl tape to prevent moisture and foreign matter from entering. I38555 7. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the bolt and disconnect the cooler unit refrigerant liquid pipe E from the condenser assy (w/ receiver). (b) Remove the Oring from the cooler refrigerant liquid pipe E. Seal the openings of the disconnected parts of the cooler unit refrigerant liquid pipe E and the condenser assy using vinyl tape to prevent moisture and foreign matter from entering. 8. REMOVE RADIATOR SUPPORT SUBASSY UPPER RH (a) Remove the 4 bolts and then the radiator support sub assy upper RH. I38556 2004 Prius Preliminary Release (RM1075U) 779

W/RECEIVER CONDENSER ASSY 5541 9. REMOVE RADIATOR SUPPORT SUBASSY UPPER LH (a) Remove the 4 bolts and then the radiator support sub assy upper LH. I38982 10. REMOVE W/RECEIVER CONDENSER ASSY (a) Remove the 2 angles. I38557 (b) Remove the 2 bolts and then the condenser assy (w/ receiver). I38558 11. REMOVE COOLER DRYER (a) Using the straight hexagon wrench 14mm (0.55 in.), remove the cap from the modulator. 14 mm (0.55 in.) Hexagon Wrench Modulator I32993 (b) Remove the Oring from the cap. E55408 I32475 2004 Prius Preliminary Release (RM1075U) 780

5542 W/RECEIVER CONDENSER ASSY (c) Using pliers, remove the cooler dryer. I32994 12. INSTALL COOLER DRYER (a) Using pliers, install the cooler dryer to the modulator. (b) Install a new Oring to the cap. I32994 E55408 (c) Sufficiently apply compressor oil (NDOIL11) to the O ring and cap fitting surface. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Using a straight hexagon wrench 14mm (0.55 in.), install the cap to the cooler condenser core. Torque: 2.9 N m (30 kgf cm, 25 in. lbf) 14 mm (0.55 in.) Hexagon Wrench Modulator I32993 13. INSTALL W/RECEIVER CONDENSER ASSY (a) Install the condenser assy (w/ receiver) with 2 bolts. Torque: 3.9 N m (40 kgf cm, 35 in. lbf) I38558 2004 Prius Preliminary Release (RM1075U) 781

W/RECEIVER CONDENSER ASSY 5543 (b) Install the 2 angles to the condenser assy (w/ receiver). I38557 (A) (C) (A) (B) I38556 14. INSTALL RADIATOR SUPPORT SUBASSY UPPER RH (a) Install the radiator support subassy upper RH with the 4 bolts. Torque: Bolt A: 5.0 N m (51 kgf cm, 44 in. lbf) Bolt B: 3.9 N m (40 kgf cm, 35 in. lbf) Bolt C: 7.5 N m (76 kgf cm, 66 in. lbf) (A) (C) (A) (B) I38982 15. INSTALL RADIATOR SUPPORT SUBASSY UPPER LH (a) Install the radiator support subassy upper LH with the 4 bolts. Torque: Bolt A: 5.0 N m (51 kgf cm, 44 in. lbf) Bolt B: 3.9 N m (40 kgf cm, 35 in. lbf) Bolt C: 7.5 N m (76 kgf cm, 66 in. lbf) 16. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the attached vinyl tape from the disconnected parts of the cooler refrigerant liquid pipe E and condenser assy (w/ receiver). (b) Install a new Oring to the cooler refrigerant liquid pipe E. (c) Sufficiently apply compressor oil (NDOIL11) to the O ring and the cooler refrigerant liquid pipe E fitting surface. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. 2004 Prius Preliminary Release (RM1075U) 782

5544 W/RECEIVER CONDENSER ASSY I38555 (d) Install the cooler refrigerant liquid pipe E to the condenser assy (w/ receiver) with the bolt. Torque: 5.4 N m (55 kgf cm, 47 in. lbf) 17. INSTALL DISCHARGE HOSE SUBASSY (a) Remove the attached vinyl tape from the disconnected parts of the discharge hose subassy and the condenser assy (w/ receiver). (b) Install a new Oring to the discharge hose subassy. (c) Sufficiently apply compressor oil (NDOIL11) to the O ring and the discharge hose fitting surface. Compressor oil: NDOIL 11 or equivalent Do not use any compressor oil other than NDOIL11 (see page 551). If any compressor oil other than NDOIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Install the discharge hose to the condenser assy (w/ receiver) with the bolt. Torque: 5.4 N m (55 kgf cm, 47 in. lbf) I38554 18. INSTALL INVERTER BRACKET NO.1 (SEE PAGE 1633) 19. INSTALL FRONT BUMPER COVER 20. INSTALL FRONT FENDER LINER RH 21. INSTALL FRONT FENDER LINER LH 22. CHARGE REFRIGERANT (SEE PAGE 5512) SST 0711058060 (0711758060, 0711758070, 0711758080, 0711758090, 0711778050, 0711788060, 0711788070, 0711788080) Specified amount: 450 30 g (15.87 1.05 oz.) 23. WARM UP COMPRESSOR (SEE PAGE 5512) 24. INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 5512) 2004 Prius Preliminary Release (RM1075U) 783

HEATER WATER PUMP ASSY REPLACEMENT HEATER WATER PUMP ASSY 5545 5519N01 1. DISCONNECT HEATER WATER HOSE C (a) Disengage the clip and disconnect the wire harness. Clip I38851 (b) Slide the hose clip and then disconnect the heater water hose C. Do not apply excessive force to the heater water hose C. Prepare a drain pan or cloth for when the cooling water leaks. I38852 2. REMOVE HEATER WATER PUMP ASSY (a) Disconnect the connector. (b) Remove the 2 bolts and then disconnect the heater water pump assy. I38969 (c) Slide the hose clip and then disconnect the heater water hose A. (d) Remove the heater water pump assy. Do not apply excessive force to the heater water hose A. Prepare a drain pan or cloth for when the cooling water leaks. I38968 2004 Prius Preliminary Release (RM1075U) 784

5546 HEATER WATER PUMP ASSY L H Ditch 3. INSTALL HEATER WATER PUMP ASSY (a) Install the heater water hose A with the hose clip. Ensure that the hose ditch faces upwards. Install the hose clip in the direction as shown in the illustration. I38971 (b) Install the heater water pump assy with the 2 bolts. Tighten them in the order indicated in the illustration. (c) Connect the connector. I38969 WR H Pink 4. INSTALL HEATER WATER HOSE C (a) Install the heater water hose C with the hose clip. Install the hose marking facing upwards. Install the hose clip in the direction as shown in the illustration. I38970 5. ADD ENGINE COOLANT (SEE PAGE 1611) 6. CHECK FOR ENGINE COOLANT LEAKS (SEE PAGE 1611) 2004 Prius Preliminary Release (RM1075U) 785

AIR CONDITIONING AMPLIFIER ASSY AIR CONDITIONING AMPLIFIER ASSY REPLACEMENT 1. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (SEE PAGE 7113) 2. REMOVE AIR DUCT REAR NO.3 (SEE PAGE 5517) 5547 5519O01 3. REMOVE AIR CONDITIONING AMPLIFIER ASSY (a) Disconnect the connector. (b) Remove the 2 screws and then the air conditioning amplifier assy. I38972 2004 Prius Preliminary Release (RM1075U) 786