BLOWER UNIT INSTALLATION


  1. INSTALL FRONT HEATER BLOWER ASSEMBLY


    1. A01KG1C

      Install the front heater blower assembly with the 3 bolts and the nut.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf, for bolts }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for nut }

    2. Connect the heater blower motor connector.

  2. INSTALL AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY


    1. A01KGLGE03
      Text in Illustration
      *a Clamp

      Connect the air inlet damper control cable sub-assembly to the heater control assembly, keeping the mode control lever in the FRESH position.

    2. Insert the top of the inner cable into the tip of the control lever (while it is in the FRESH position).

    3. Insert the outer cable into the clamp while pulling it slightly in the direction indicated by the arrow in the illustration.

      CAUTION:

      When operating the mode control lever, check that there is looseness in both the FRESH and RECIRC positions, and that there is no interference..

  3. INSTALL NO.1 AIR DUCT SUB-ASSEMBLY (for Wide Body)

  4. INSTALL COOLER UNIT ASSEMBLY

  5. INSTALL WINDSHIELD WASHER JAR ASSEMBLY

    A01KFSD

    1. Connect the hose and connector to the washer pump.

    2. A01KFM9

      Install the windshield washier jar with the 2 bolts.

  6. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

  7. INSTALL INSTRUMENT COVER LOWER CENTER

  8. INSTALL INSTRUMENT COVER LWR (for Wide Body)

  9. CONNECT LIQUID HOSE A

  10. CONNECT COOLER REFRIGERANT SUCTION HOSE

  11. INSTALL HEATER AIR FILTER

  12. ADD ENGINE COOLANT


    1. Slowly fill the system with coolant.


      • Use of improper coolants may damage engine cooling system.


      • Use "Toyota Long Life Coolant" or equivalent and mix it with plan water according to the manufacturer's directions.


      • Using of coolant which includes more than 50 % [freezing protection down to -35°C (-31°F)] or 60 % [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended but not more than 70 %.

      Note


      • Do not use an alcohol type coolant or plain water alone.


      • The coolant should be mixed with plain water (preferably demineralized water or distilled water).

        Capacity:
        Independent Front Suspension Rigid Front Suspension
        w/ Front heater

        10.7 liters

        (11.3 US qts, 9.4 Imp. qts)

        10.9 liters

        (11.5 US qts, 9.6 Imp. qts)
        w/o heater

        9.8 liters

        (10.4 US qts, 8.6 Imp. qts)

        10 liters

        (10.6 US qts, 8.8 Imp. qts)
        w/ Front and Rear heater

        11.5 liters

        (12.2 US qts, 10.1 Imp. qts)

        11.7 liters

        (12.3 US qts, 10.3 Imp. qts)

    2. Reinstall the radiator cap.

    3. Start the engine, and bleed the cooling system.

    4. Refill the radiator reservoir with coolant until it reaches the "full" line.

  13. CHARGE REFRIGERANT

  14. WARM UP ENGINE

  15. CHECK FOR COOLANT LEAKS

    A01KHUQE01
    Text in Illustration
    *1 Radiator Cap Tester

    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

  16. CHECK FOR REFRIGERANT LEAKS

  17. INSTALL HEADLAMP UNIT ASSEMBLY LH


    1. A01KHYNE01
      Text in Illustration
      *1 Socket Cover
      *2 Bulb
      *3 Lamp Cover
      A01KFMEE01
      Text in Illustration
      *1 Socket Cover
      *2 Bulb

      Install the socket cover.

      Note


      • Push in until the socket cover peripheral hits the lamp body.

      • Push the valve girth of the socket cover in until whole the metal parts of the valve can be checked.

  18. INSTALL CLEARANCE LAMP LENS & BODY LH (for LHD)

  19. INSTALL RADIATOR GRILLE