AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

    Note


    • Be sure to support the air conditioner unit assembly when installing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.

    • When installing the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. Engage the 2 guides to temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

      B005LC8C01
      B005OOA Install in this Direction - -

    2. Connect each connector.

    3. Install the 4 bolts (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    4. Connect the brake pedal support assembly with the 2 bolts (B).

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    5. Temporarily install the nut.

    6. Engage the claw to connect the drain cooler hose to the piping clamp.

    7. Install the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    8. Install the 2 hole plugs.

  3. INSTALL BRAKE PEDAL RETURN SPRING

    for LHD:

    Click here

    for RHD:

    Click here

  4. INSTALL INSTRUMENT PANEL WIRE


    1. for LHD:


      1. Engage each clamp.

      2. Connect each connector.

      3. Connect the ECU integration box RH with the bolt (B) and 2 nuts (D).

        Torque:
        Nut (D)
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      4. Connect the connector holder with the 2 nuts (C).

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      5. Connect the instrument panel wire with the nut (B).

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      6. Connect the instrument panel wire with the nut (A).

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      7. Connect the earth wire with the bolt (A).

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. for RHD:


      1. Engage each clamp.

      2. Connect each connector.

      3. w/ Panoramic View Monitor System:

        Connect the parking assist ECU with the 2 nuts (D).

      4. Connect the connector holder with the 2 nuts (C).

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      5. Connect the instrument panel wire with the nut (B).

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      6. Connect the instrument panel wire with the nut (A).

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      7. Connect the earth wire with the bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  5. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. Engage the 6 claws to install the No. 1 air duct sub-assembly.

    2. Engage the clamp.

  6. INSTALL CENTER HEATER TO REGISTER SUB DUCT


    1. Install the center heater to register sub duct with the 3 clips.

  7. INSTALL INSTRUMENT PANEL REINFORCEMENT SUB-ASSEMBLY


    1. Install the instrument panel reinforcement sub-assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  8. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. Install the No. 2 instrument panel brace sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. Engage each clamp.

  9. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. Install the No. 1 instrument panel brace sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. Engage each clamp.

  10. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.

      B005OO1C01
      B005NIZ Bolt B005LWS Screw
      B005N37 Nut - -
      Torque:
      Bolt
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      Tighten the bolts, screws and nut in the order shown in the illustration.

  11. INSTALL PARKING ASSIST ECU (w/ Panoramic View Monitor System)

    for LHD:

    Click here

  12. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    for LHD:

    Click here

    for RHD:

    Click here

  13. INSTALL ECU INTEGRATION BOX LH (for RHD)

    Click here

  14. INSTALL DOUBLE LOCK DOOR CONTROL RELAY ASSEMBLY (w/ Double Locking System)

    Click here

  15. INSTALL REAR NO. 3 AIR DUCT


    1. Engage the 2 claws to install the rear No. 3 air duct.

  16. INSTALL REAR NO. 4 AIR DUCT


    1. Engage the claw to install the rear No. 4 air duct.

    2. Install the clip.

    3. B005P80

      Install the front floor carpet assembly to its original position as shown in the illustration.

    4. Engage the 4 guides.

  17. INSTALL REAR NO. 1 AIR DUCT


    1. Engage the 2 claws to install the rear No. 1 air duct.

    2. Engage each clamp.

  18. INSTALL REAR NO. 2 AIR DUCT


    1. Engage the claw to install the rear No. 2 air duct.

    2. Install the clip.

    3. B005P6S

      Install the front floor carpet assembly to its original position as shown in the illustration.

    4. Engage the 4 guides.

  19. INSTALL NO. 1 CONSOLE BOX DUCT

    Click here

  20. INSTALL SHIFT AND SELECT LEVER SUPPORT

    Click here

  21. INSTALL NO. 3 CONSOLE BOX MOUNTING BRACKET

    Click here

  22. INSTALL TELEMATICS TRANSCEIVER WITH BRACKET (w/ Telematics Transceiver for G-BOOK)

    Click here

  23. INSTALL TELEMATICS TRANSCEIVER (w/ Telematics Transceiver except G-BOOK)

    Click here

  24. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

    for U661E Automatic Transmission / Transaxle:

    Click here

    for U661F Automatic Transmission / Transaxle:

    Click here

    for U881E Automatic Transmission / Transaxle:

    Click here

    for U881F Automatic Transmission / Transaxle:

    Click here

  25. INSTALL ACCELERATOR PEDAL

    for 8AR-FTS:

    Click here

    for 2GR-FKS:

    Click here

  26. INSTALL ACCELERATOR PEDAL PAD

    for 8AR-FTS:

    Click here

    for 2GR-FKS:

    Click here

  27. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  28. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  29. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  30. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  31. CONNECT INLET HEATER WATER HOSE


    1. B005PATC01
      *a View A
      *b

      for 8AR-FTS:

      Marking (Red)

      for 2GR-FKS:

      Marking (White)
      *c Clip Installation Angle (90°)

      Connect the inlet heater water hose with the marking facing left and engage the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the inlet heater water hose.

  32. CONNECT OUTLET HEATER WATER HOSE


    1. B005PVUC01
      *a View A
      *b

      for 8AR-FTS:

      Marking (Red)

      for 2GR-FKS:

      Marking (White)
      *c Clip Installation Angle (90°)

      Connect the outlet heater water hose with the marking facing left and engage the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the outlet heater water hose.

  33. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioner tube and accessory assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the air conditioner tube and accessory assembly.

  34. CONNECT NO. 2 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (w/ Sub-cool Accelerator)


    1. Remove the vinyl tape from the No. 2 air conditioner tube and accessory assembly.

    2. Sufficiently apply compressor oil to a 2 new O-rings and the fitting surfaces of the No. 2 air conditioner tube and accessory assembly.

      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

    3. Install the 2 O-rings to the No. 2 air conditioner tube and accessory assembly.

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. Connect the No. 2 air conditioner tube and accessory assembly.

    5. B005LBZ

      Rotate the hook connector as shown in the illustration.

    6. Insert the hose joint into the fitting hole securely and install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  35. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)


    1. Remove the vinyl tape from the suction pipe sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the suction pipe sub-assembly.

    5. B005POL

      Rotate the hook connector as shown in the illustration.

    6. Insert the hose joint into the fitting hole securely and install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  36. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  37. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  38. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    Click here

  39. ADD ENGINE COOLANT

    for 8AR-FTS:

    Click here

    for 2GR-FKS:

    Click here

  40. INSPECT FOR COOLANT LEAK

    for 8AR-FTS:

    Click here

    for 2GR-FKS:

    Click here

  41. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  42. WARM UP ENGINE

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  43. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  44. INITIALIZATION SERVO MOTOR

    Click here