AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Engage the 2 claws.

    2. 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. Connect each connector.

      B006YEGC01
      *A for LHD *B for RHD
      B006ZFL Install in this Direction - -

    2. Engage each clamp.

    3. Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

    4. Install the 4 bolts (A).

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

    5. Connect the brake pedal assembly with the bolt (B).

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    6. Temporarily install the nut.

    7. Install the 3 bolts.

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

    8. Install the 2 hole plugs.

    9. B007129C01
      *a Lip

      Install a new cooler unit drain hose grommet.

      Note


      • If the drain cooler hose is disconnected from the cooler unit drain hose grommet, make sure to replace the cooler unit drain hose grommet with a new one. Failure to do so may lead to water ingress.

      • Make sure that the entire lip of the cooler unit drain hose grommet is securely engaged to the vehicle body.

    10. Connect the drain cooler hose.

    11. B0070YL

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

    12. B006YNXC01
      *A w/ Smart Entry and Start System
      *a Lock Lever
      B006Z38 Move in this Direction

      Engage each clamp.

    13. Temporarily connect the connector and then move the lock lever in the direction indicated by the arrow to securely connect the connector.

      Note

      When connecting any airbag connector, take care not to damage the airbag wire harness.

    14. Check that there is no looseness in the installed parts of the airbag sensor assembly.

    15. w/ Smart Entry and Start System:


      1. Connect the connector.

    16. for LHD:


      1. Engage each clamp.

      2. Connect the connector holder with the 2 nuts.

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

      3. Connect the 3 earth wires with the 3 bolts.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      4. Connect the connector.

    17. for RHD:


      1. Engage the clamp.

      2. Connect the connector holder with the 2 nuts.

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

      3. Engage each clamp.

      4. Connect the 3 earth wires with the 3 bolts.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      5. Connect each connector.

  3. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. Engage the 4 claws to install the No. 2 air duct sub-assembly.

  4. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for LHD)

    Click here

  5. INSTALL ECU INTEGRATION BOX RH (for RHD)

    w/ ECU Integration Box RH:

    Click here

  6. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

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

    2. Engage each clamp.

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


    1. Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. Engage each clamp.

    4. for LHD:


      1. Connect the relay block assembly with the bolt (B).

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

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

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    5. for RHD:


      1. Connect the earth wire with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

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


    1. Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. Engage each clamp.

    4. for LHD:


      1. Connect the earth wire with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    5. for RHD:


      1. Connect the relay block assembly with the bolt (B).

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

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

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  9. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. for LHD:


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

        B006X5RC01
        B006Z38 Bolt B006ZY0 Screw
        B006YM5 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.

    2. for RHD:


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

        B006YQBC01
        B006Z38 Bolt B006ZY0 Screw
        B006YM5 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.

  10. INSTALL NO. 3 DASH PANEL INSULATOR PAD


    1. B006Y33

      Install the No. 3 dash panel insulator pad with 2 new clips as shown in the illustration.

  11. INSTALL NO. 1 CONSOLE BOX DUCT


    1. B0070QSC01
      B006ZFL Install in this Direction

      Install the No. 1 console box duct as shown in the illustration.

  12. INSTALL FLOOR CARPET BRACKET LH


    1. B0070QLC01
      B006ZFL Install in this Direction

      Engage the claw as shown in the illustration.

    2. Install the floor carpet bracket LH with the clip.

  13. INSTALL FLOOR CARPET BRACKET RH


    1. B006XHZC01
      B006ZFL Install in this Direction

      Engage the claw as shown in the illustration.

    2. Install the floor carpet bracket RH with the clip.

  14. INSTALL REAR NO. 3 AIR DUCT


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

  15. INSTALL REAR NO. 4 AIR DUCT


    1. B00703MC01
      B006ZFL Install in this Direction

      Engage the 4 claws to install the rear No. 4 air duct as shown in the illustration.

    2. B0070RR

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

    3. Engage the 2 guides.

    4. Install the 2 front floor carpet clips.

  16. INSTALL REAR NO. 1 AIR DUCT


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

  17. INSTALL REAR NO. 2 AIR DUCT


    1. B006ZZTC01
      B006ZFL Install in this Direction

      Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.

    2. B0071UJ

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

    3. Engage the 2 guides.

    4. Install the front floor carpet clip.

    5. for LHD:


      1. Install the front floor carpet clip.

  18. INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. B006XZRC01
      B006ZFL Install in this Direction (1)
      B006WSJ Install in this Direction (2)

      Engage the guide and claw to install the front floor caution plate cover as indicated by the arrows, in the order shown in the illustration.

  19. INSTALL ACCELERATOR PEDAL

    for 2AR-FE:

    Click here

    for A25A-FKS:

    Click here

    for 2GR-FKS:

    Click here

  20. INSTALL ACCELERATOR PEDAL PAD

    for 2AR-FE:

    Click here

    for A25A-FKS:

    Click here

    for 2GR-FKS:

    Click here

  21. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.

  22. INSTALL CENTRAL GATEWAY ECU (NETWORK GATEWAY ECU) (w/o Smart Entry and Start System)

    Click here

  23. INSTALL ECU INTEGRATION BOX RH (for LHD)

    w/ ECU Integration Box RH:

    Click here

  24. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for RHD)

    Click here

  25. INSTALL DOOR CONTROL BATTERY (w/ Door Control Battery)

    Click here

  26. INSTALL NO. 1 CLEARANCE WARNING BUZZER (for LHD)

    w/ TOYOTA Parking Assist-sensor System:

    Click here

  27. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  28. INSTALL STEERING COLUMN ASSEMBLY

    for Manual Tilt and Manual Telescopic Steering Column:

    Click here

    for Power Tilt and Power Telescopic Steering Column:

    Click here

  29. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

    for UA80E:

    Click here

    for UB80E:

    Click here

    for U760E:

    Click here

  30. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  31. INSTALL FRONT SEAT ASSEMBLY RH

    for Manual Seat:

    Click here

    for Power Seat:

    Tech Tips

    Use the same procedure as for the LH side.

  32. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


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

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

      Compressor Oil
      ND-OIL 8 or equivalent

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

      Note

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

    4. Connect the air conditioning tube and accessory assembly.

  33. CONNECT SUCTION PIPE SUB-ASSEMBLY


    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. B0071RL

      Rotate the hook connector as shown in the illustration.

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

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

  34. CONNECT INLET HEATER WATER HOSE


    1. for A25A-FKS:


      1. B006Z5FC01
        *a View A
        *b Marking (White)
        *c Clip Installation Angle (270°)

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

        Note

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

    2. except A25A-FKS:


      1. B0070I7C01
        *a View A
        *b

        for 2AR-FE:

        Marking (Red)

        for 2GR-FKS:

        Marking (Purple)
        *c Clip Installation Angle (270°)

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

        Note

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

  35. CONNECT OUTLET HEATER WATER HOSE


    1. B0071MQC01
      *a View A
      *b

      for 2AR-FE:

      Marking (Red)

      for A25A-FKS:

      Marking (Red)

      for 2GR-FKS:

      Marking (Purple)
      *c Clip Installation Angle (270°)

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

      Note

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

  36. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

    for LHD:

    Click here

    for RHD:

    Click here

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  38. ADD ENGINE COOLANT

    for 2AR-FE:

    Click here

    for A25A-FKS:

    Click here

    for 2GR-FKS:

    Click here

  39. INSPECT FOR COOLANT LEAK

    for 2AR-FE:

    Click here

    for A25A-FKS:

    Click here

    for 2GR-FKS:

    Click here

  40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  41. WARM UP ENGINE

    Click here

  42. INSPECT FOR REFRIGERANT LEAK

    Click here