REAR COOLING UNIT INSTALLATION


  1. INSTALL REAR COOLING UNIT ASSEMBLY


    1. A017FV4E01

      Install the rear cooling unit assembly with the 4 bolts.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    2. A017B2U

      Connect each connector.

    3. Engage each clamp.

  2. INSTALL REAR NO. 5 AIR DUCT


    1. A017F7Y

      Install the rear No. 5 air duct with the 2 clips.

  3. INSTALL NO. 1 COOLER AIR DUCT


    1. A017F8AE01

      Install the No. 1 cooler air duct as shown in the illustration.

  4. INSTALL COOLER PLATE


    1. A017E65

      Engage the 2 claws and install the cooler plate.

  5. INSTALL ROOF SIDE INNER GARNISH ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  6. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH


    1. Engage the 4 clips and 7 claws.

    2. Install the 2 clips.

    3. Install the deck trim side panel assembly RH with the 3 bolts.

      A017FTC

  7. INSTALL FRONT DECK SIDE TRIM COVER RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  8. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK

    Tech Tips

    Use the same procedure for the No. 1 luggage compartment trim hook and the No. 2 deck side trim hook.

  9. INSTALL ROPE HOOK ASSEMBLY (for RH Side)

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  10. INSTALL REAR COMBINATION LIGHT SERVICE COVER RH


    1. A017DDV

      Engage the 2 guides and 6 claws, and install the rear combination light service cover RH.

  11. INSTALL SIDE TRIM COVER RH (for Manual Air Conditioning System)


    1. A017CSI

      Engage the 4 claws, and install the side trim cover RH.

  12. INSTALL REAR ROOM TEMPERATURE SENSOR (for Automatic Air Conditioning System)


    1. Connect the connector.

    2. A017B3P

      Engage the 4 claws and install the rear room temperature sensor.

  13. INSTALL DECK SIDE TRIM RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  14. INSTALL DECK SIDE TRIM COVER NO.1

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  15. INSTALL REAR SEAT SIDE GARNISH CAP


    1. A017ER4

      Engage the guide and 6 claws.

    2. Install the rear seat side garnish cap with the screw.

  16. INSTALL REAR FLOOR FINISH PLATE


    1. A017BSY

      Engage the 4 clips and 4 claws, and install the rear floor finish plate.

  17. INSTALL REAR NO. 2 SEAT ASSEMBLY

    Click here

  18. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH


    1. A017FFPE01

      Align the alignment mark (green) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the rear door opening trim weatherstrip RH.

      Note

      After installation, check that the corners fit correctly.

  19. INSTALL REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  20. CONNECT COOLER REFRIGERANT LIQUID PIPE C


    1. Remove the attached vinyl tape from the tube.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe C.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the cooler refrigerant liquid pipe C.

    4. Install the cooler refrigerant liquid pipe C.

  21. CONNECT COOLER REFRIGERANT SUCTION HOSE


    1. Remove the attached vinyl tape from the hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant suction hose.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the cooler refrigerant suction hose.

    4. Move the hook connector in the direction indicated by the arrow in the illustration.

    5. A017CXS

      Insert the pipe joint into the fitting hole securely and tighten the bolt.

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

  22. CONNECT REAR HEATER INLET WATER HOSE


    1. A017CFR

      Install the water hose and attach the clip.

  23. CONNECT REAR HEATER OUTLET WATER HOSE


    1. A017DZ6

      Install the water hose and attach the clip.

  24. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A017FV6E02
      Standard (w/o Rear Air Conditioning System)
      550 to 650 g (19.4 to 22.9 oz.)
      Standard (w/ Rear Air Conditioning System)
      720 to 820 g (25.4 to 28.9 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.

      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

  25. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for cylinder block drain cock plugs }

    3. Loosen the air drain cock plug from the water inlet housing.

    4. A017G9AE01

      Loosen the air drain plug at the top of the radiator 3 or 4 turns.

    5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for air drain cock plug }

    6. Continue to add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the radiator air drain hole. Then close the air drain plug at the top of the radiator.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf, for air drain plug }

      Tech Tips

      If the coolant level at the radiator inlet opening drops after squeezing the No. 1 and No. 2 radiator hoses, add coolant.

    7. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Standard capacity
      Condition Specified Condition
      w/ Rear Heater 11.7 liters (12.4 US qts, 10.3 Imp. qts)
      w/o Rear Heater 9.5 liters (10.1 US qts, 8.4 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    8. Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

    9. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    10. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When squeezing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

        Note


        • Make sure that the radiator reservoir still has some coolant in it.

        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • If there is not enough coolant, the engine may overheat or be seriously damaged.

        • If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line.

    11. Stop the engine and wait until the engine coolant cools down.

    12. Add engine coolant to the FULL line on the radiator reservoir.

  26. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. A017G83

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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

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

  27. WARM UP ENGINE


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  28. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant gas, inspect for refrigerant leak using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Make sure that the ignition switch is off.

      • Secure good ventilation (the gas leak detector may 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 the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A017BY0E25

      Using a gas leak detector, inspect for refrigerant leak from the refrigerant lines.

    4. A017DL2E06

      Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring 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 volatile gases.

        If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

    5. If a gas leak is not detected from the drain hose, remove the blower motor from the cooling unit. Insert the gas leak detector into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.