Yes, Have tried that. vents are clean.
Forgot to add that i have also done the drive around with the heater blasting and windows down. This only works for about a day or 2 as well.
I have also removed the lower foot exit vent on the passanger side and sprayed Pinoclean through a spraygun into the cavity. As you guessed, the car stank of pino for about a week, the smell came back.
I suppose the question now is. Is this a common issue with Toyota AC systems?
Would you think this issue could be covered under statutory warranties?
http://www.accc.gov.au/system/files/Warranties%20and%20refunds%20-%20a%20guide%20for%20consumers%20and%20business.pdf
Would it be unreasonable to think that if you have followed all service requirements and car owner manual advice that mold should still grow in the system?
Toyota has quoted approx $1500 to $2000 to clean the system as the whole dash needs to be removed.