AIR CONDITIONING UNIT (for 1KR-FE) INSTALLATION


  1. INSTALL AIR CONDITIONER UNIT ASSEMBLY

    Tech Tips

    If a new air conditioner unit assembly is installed, add compressor oil to the evaporator as follows.

    Compressor oil
    ZXL 200PG or equivalent
    Add 30 cc (1.06 fl.oz.)

    1. Install the air conditioner unit assembly with the clip and 5 nuts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      A0137MX

    2. Connect the 3 connectors and clamp.

      A01391V

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT


    1. Install the instrument panel reinforcement with the 6 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 21 ft.*lbf }
      A0136UE

    2. Install the bolt.

      Torque:
      3.7 N*m  { 38 kgf*cm, 32 in.*lbf }

    3. Engage the 7 clamps.

      A0138QPE01

  3. INSTALL RELAY BLOCK ASSEMBLY

    A01374PE01

    1. Engage the clamp.

    2. Install the relay block assembly with the screw.

      Torque:
      3.7 N*m  { 38 kgf*cm, 32 in.*lbf }

  4. INSTALL CONNECTOR HOLDER

    A0135XH

    1. Install the connector holder with the screw.

      Torque:
      3.7 N*m  { 38 kgf*cm, 32 in.*lbf }

  5. INSTALL DOOR CONTROL WITH RECEIVER ECU ASSEMBLY

    A0136SW

    1. Install the door control with receiver ECU assembly with the bolt.

      Torque:
      3.7 N*m  { 38 kgf*cm, 32 in.*lbf }

    2. Connect the connector.

  6. INSTALL TRANSPONDER KEY ECU ASSEMBLY

    A0137HA

    1. Connect the connector.

    2. Install the transponder key ECU assembly with the bolt.

      Torque:
      3.7 N*m  { 38 kgf*cm, 32 in.*lbf }

  7. INSTALL AIR DUCT REAR NO. 1 (for Cold Area Specification Vehicles)

    A0136E6E01

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

    2. Put the floor carpet back down.

  8. INSTALL AIR DUCT REAR NO. 2 (for Cold Area Specification Vehicles)

    A0138WME01

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

    2. Put the floor carpet back down.

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

    A0137AVE01

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

      Torque:
      29 N*m  { 300 kgf*cm, 21 ft.*lbf, for bolt }
      29 N*m  { 300 kgf*cm, 21 ft.*lbf, for nut }
      1.2 N*m  { 12 kgf*cm, 11 in.*lbf, for screw }

    2. Install the 2 wire harness clamp bolts.

    3. Engage the 2 clamps.

    4. Install the floor carpet with the clip.

  10. INSTALL STEERING COLUMN ASSEMBLY

    A0138IZ

    1. Install the steering column assembly with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    2. A0137H2

      Engage the 3 clamps and connect the wire harness.

    3. A0136LD

      Engage the 2 connectors.

    4. A0137IGE01

      Provisionally install the intermediate shaft assembly with bolt A.

    5. Align the matchmarks on the intermediate shaft assembly No. 2 and steering gear assembly.

    6. Tighten bolt B and bolt A.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  11. INSTALL STEERING COLUMN PROTECTOR NO. 1 (RHD-E/PS-MT)

    A0138PB

    1. Install the steering column protector No. 1 onto the power steering motor assembly with the bolt.

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

  12. INSTALL STEERING COLUMN HOLE COVER PLATE

    A0136Y5

    1. Engage the steering hole plate.

  13. INSTALL INSTRUMENT PANEL ASSEMBLY LOWER


    1. Install the instrument panel lower with the 2 bolts <F>, 5 screws <I> or <H>, screw <G>, screw <J> and 2 clips.

      Torque:
      3.7 N*m  { 38 kgf*cm, 33 in.*lbf, for screw <J> }

    2. Connect the connectors and 3 wire harness clamps.

      A01388AE01
    3. A0138HB

      Connect the antenna cord by engaging the 4 fastenings.

  14. INSTALL CONSOLE BOX (for Manual Transaxle)

    A01378KE01

    1. Engage the 2 claws and install the console box.

    2. Install the bolt <E>.

    3. Install the box bottom mat.

    4. Install the shift knob.

  15. INSTALL CONSOLE BOX (for Multi-Mode Manual Transaxle)

    A0137KCE02

    1. Engage the 2 claws and install the console box.

    2. Install the bolt <E>.

    3. Install the box bottom mat.

  16. INSTALL FLOOR SHIFT POSITION INDICATOR HOUSING SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    A0136QG

    1. Engage the 4 claws and install the floor shift position indicator housing sub-assembly.

    2. A0137LF

      Install the shift knob.

  17. INSTALL HEATER CONTROL ASSEMBLY (for LHD)

    A0137HM

    Note

    Do not bend the cable when installing the heater control assembly.


    1. Insert each cable into the instrument panel.

    2. A0137SPE01

      Pass the white air inlet cable between the instrument panel and wire harness.

    3. Pass the black air mix cable between the instrument panel and wire harness.

    4. Pass the blue defroster cable between the instrument panel reinforcement and wire harness, and then outside the wire harness clamp.

    5. A0138YNE01

      Engage the 2 claws and install the heater control assembly with the 2 screws.

  18. INSTALL HEATER CONTROL ASSEMBLY (for RHD)

    A0138TT

    Note

    Do not bend the cable when installing the heater control assembly.


    1. Insert the cable into the instrument panel.

    2. A0137T7E01

      Pass the white air inlet cable through the wire harness.

    3. Pass the black air mix cable between the instrument panel and brace.

    4. Pass the blue defroster cable between the instrument panel reinforcement and wire harness, and then outside the wire harness clamp.

    5. A0138YNE01

      Engage the 2 claws and install the heater control assembly with the 2 screws.

  19. SET HEATER CONTROL ASSEMBLY

    A0137FKE01

    1. Make sure that the levers are placed in the position shown in the illustration.

  20. CONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY

    A01385VE01

    1. Turn the mode link to the DEF position.

    2. Install the cable ring onto the motor link.

    3. Hold the mode wheel knob of the heater control and install the defroster cable onto the clamp while pulling it in the direction indicated by arrow A.

      Note

      Make sure that the air mix lever knob operates correctly. Also, confirm that there is no reverse movement of the knob at either end.

  21. CONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY

    A0136TQE01

    1. Turn the temperature control link to the MAX-cool position.

    2. Install the cable ring onto the temperature control link.

    3. Hold the mode wheel knob of the heater control and install the mode cable onto the clamp while pulling it in the direction indicated by arrow A.

      Note

      Make sure that the air mix lever knob operates correctly. Also, confirm that there is no reverse movement of the knob at either end.

  22. CONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY

    A01363GE01

    1. Turn the air inlet control link to the RECIRCULATION position.

    2. Turn the air inlet control link to the FRESH AIR position.

    3. Install the cable ring onto the air inlet control link.

    4. Hold the air inlet lever knob of the heater control and install the air inlet cable onto the clamp while pulling it in the direction indicated by arrow A.

      Note

      Make sure that the air inlet lever knob operates correctly. Also, confirm that there is no reverse movement of the knob at either end.

  23. INSTALL COWL SIDE TRIM BOARD LH


    1. A0137W2E01

      Engage the 2 clips and claw, and install the cowl side trim board LH.

  24. INSTALL COWL SIDE TRIM BOARD RH

  25. INSTALL INSTRUMENT PANEL ASSEMBLY


    1. Engage the 4 clips and 5 claws and install the instrument panel assembly.

      Note

      Make sure that there are no gaps between the instrument panel upper and instrument panel lower panel.

      A0138IQ

    2. Install the bolt <A>, 2 nuts <D> and 2 screws <B>.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf, for bolt <A> }
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf, for nut <D> }
      A0137GXE01
    3. A0138UJ

      Connect the airbag connector, as shown in the illustration.

    4. A0136KRE02

      Engage the 2 claws and close the cover.

  26. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER

    A0136KWE02

    1. Connect the connectors.

    2. Engage the 4 clips and 3 claws and install the instrument cluster finish panel center.

    3. Install the screw.

    4. Install the control knob.

  27. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    A0136BT

    1. Connect the connector.

    2. A01362K

      Install the 2 screws.

  28. INSTALL INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY NO. 2

    A0136QKE01

    1. Engage the 2 claws.

  29. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

  30. INSTALL INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY NO. 1

  31. INSTALL FRONT PILLAR GARNISH RH (w/ Curtain Shield Airbag)

    A0138GXE01

    1. Remove the adhesive tape and protective cover.

    2. A0138EWE01

      Install a new clip.

    3. Engage the 2 claws and 2 clips, and install the front pillar garnish.

  32. INSTALL FRONT PILLAR GARNISH LH (w/ Curtain Shield Airbag)

    Tech Tips

    Use the same procedure as for the RH side.

  33. INSTALL FRONT PILLAR GARNISH RH (w/o Curtain Shield Airbag)

    A01391L

    1. Engage the 2 claws and 2 clips, and install the front pillar garnish.

  34. INSTALL FRONT PILLAR GARNISH LH (w/o Curtain Shield Airbag)

    Tech Tips

    Use the same procedure as for the RH side.

  35. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH

    A01380D

    1. Install the front door opening trim weatherstrip.

  36. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

  37. INSTALL COMBINATION SWITCH ASSEMBLY


    1. A0137JG

      Engage the 2 claws and install the combination switch assembly, as shown in the illustration.

    2. A0138EYE01

      Install the combination switch assembly with the clamp.

    3. A01362T

      Connect the 3 connectors.

  38. INSTALL SPIRAL CABLE SUB-ASSEMBLY

    A01383L

    1. Check that the front wheels are facing straight ahead.

    2. Set the turn signal switch in the neutral position.

      Note

      Make sure that the turn signal switch is in the neutral position or the pin of the turn signal switch may be snapped.

    3. Engage the 3 claws and install the spiral cable.

      Note

      When replacing the spiral cable with a new one, remove the lock pin before installing the steering wheel.

    4. Connect the steering angle sensor connector (w/ VSC).

    5. Connect the airbag connector, as shown in the illustration.

      Note

      When handling the airbag connector, do not damage the airbag wire harness.

    6. Connect the horn connector.

  39. INSTALL COMBINATION METER ASSEMBLY

    A0137AB

    1. Connect the 14 connectors.

    2. Install the combination meter with the 2 bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  40. INSTALL TACHOMETER ASSEMBLY (w/ Tachometer)

    A0135U6

    1. Install the tachometer with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    2. Connect the connector.

  41. INSTALL STEERING COLUMN LOWER COVER

    A0136RZ

    1. Install the steering column lower cover with the screw.

  42. INSTALL STEERING COLUMN UPPER COVER

    A0136TV

    1. Install the steering column cover upper, as shown in the illustration (w/ tachometer).

    2. A0136OJE02

      While turning the steering wheel to the right and left, engage the 4 claws and install the steering column cover upper with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    3. A0137VI

      Tighten the screw behind the tachometer (w/ tachometer).

      Note

      Tighten the screw if the tachometer has been extended and the column cover has been removed.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  43. ADJUST SPIRAL CABLE SUB-ASSEMBLY

    A0138C8

    1. Check that the ignition switch is turned to OFF.

    2. Check that the cable is disconnected from the negative battery terminal.

      CAUTION:

      After disconnecting the cable from the negative battery terminal, wait for at least 90 seconds before starting the operation.

    3. Turn the spiral cable counterclockwise slowly by hand until it feels firm.

    4. A01368AE01

      Rotate the spiral cable clockwise approximately 2.5 turns until the marks are matched again.

      Tech Tips

      The spiral cable will rotate approximately 2.5 turns to both left and right of the center.

  44. INSTALL STEERING WHEEL ASSEMBLY


    1. Align the matchmarks on the steering wheel assembly and steering main shaft assembly.

    2. Install the steering wheel assembly set nut.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  45. INSTALL HORN BUTTON ASSEMBLY

    A0136JY

    1. Support the steering pad with one hand, as shown in the illustration.

    2. Connect the airbag connector, as shown in the illustration.

      Note

      When handling the airbag connector, do not damage the airbag wire harness.

    3. Connect the horn connector.

    4. A0138S9E01

      Confirm that the circumference groove of the screw fits into the screw case, and place the steering pad onto the steering wheel.

    5. Using "Torx" socket wrench T30, tighten the 2 screws.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  46. INSTALL HEATER WATER OUTLET HOSE

    A0136X6E01

    1. Install the heater water outlet hose onto the heater unit.

      Note

      Perform the installation with the hose clip and mark at the correct angle.

  47. INSTALL HEATER WATER INLET HOSE

    A0136R1E01

    1. Install the heater water inlet hose onto the heater unit.

      Note

      Perform the installation with the hose clip and mark at the correct angle.

  48. INSTALL SUCTION HOSE SUB-ASSEMBLY

    A0136ZI

    1. Apply compressor oil to 2 new O-rings and install them onto the tube.

      Compressor oil
      ZXL 200PG or equivalent

    2. Install the suction hose and air conditioning tube with the bolt.

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

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  50. ADD ENGINE COOLANT


    1. Connect the engine side radiator outlet hose .

    2. A0137DX

      Install the cylinder block drain cock plug.

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

    3. Pour engine coolant into the radiator assembly until it is full.

      Capacity
      Specification Capacity
      except Tropic Spec 4.0 liters (4.2 US qts, 3.5 Imp qts)
      for Tropic Spec 4.4 liters (4.6 US qts, 3.9 Imp qts)

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. Install the radiator cap sub-assembly securely.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. 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.

      2. The thermostat open timing can be confirmed by pressing the outlet radiator hose by hand, and checking when the coolant starts to flow inside the hose.

      3. Maintain the engine speed at 2500 to 3000 rpm and warm up the engine until the cooling fan operates.

      4. Press the outlet radiator hose and inlet radiator hose several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

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

    9. If the engine coolant level is below the full level, perform steps (c) through (h) and repeat the operation until the engine coolant level stays the full level.

    10. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add engine coolant.

  51. CHECK FOR ENGINE COOLANT LEAKAGE

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A01375K

      Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

    2. Warm up the engine.

    3. Pump it to 137 kpa (1.4 kgf*cm2, 19.9 psi), then check that the pressure does not drop.


      • If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.

    4. Be sure not to put more than 177 kpa (1.8 kgf*cm2, 25.6 psi).

  52. CHARGE REFRIGERANT

    SST
    07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )
    A0138NSE02

    Note

    Be sure to charge refrigerant in accordance with equipment manual.


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      420 to 480g (14.81 to 16.93oz.) for IKR-FE
      470 to 530g (16.58 to 18.69oz.) for 2WZ-TV

      Note

      Do not start the engine before charging it with refrigerant as the cooler compressor doesn't work properly without sufficient refrigerant. This could cause the compressor to overheat.

      Tech Tips


      • The relationship between refrigerant charge amount and pressure is as follows.

        A0136RSE02

      • Correct charging amount is approximately 450g.

      • High Charge Range:

        If refrigerant is overcharged, pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.

      • Low Charge Range:

        Shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens compressor life. Operation with insufficient coolant raises refrigerant temperature and causes heat deterioration of rubber seals and hoses. Cracking and thus refrigerant leakage may occur.


      1. Install the caps onto the service valves on the refrigerant line.

  53. WARM UP ENGINE

    Note

    Warm up the engine at less than 2,000 rpm for 1 minute or more after charging it with refrigerant.

  54. CHECK FOR REFRIGERANT LEAKAGE


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation as follows:


      • Stop the engine.

      • Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf*cm2, 57 to 85 psi)

      Tech Tips

      It is impossible for the above pressure to be maintained if there is leakage.

    3. A0137K1E01

      Using a gas leak detector, check the refrigerant line, especially the connecting points, for leakage.

    4. A0137F7E01

      Bring the gas leak detector close to the drain hose before performing the test.

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for at least 15 minutes.

      • Place 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 the volatile gases.

      If such a reaction is unavoidable, the vehicle must be lifted up.

    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 sensor 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.

  55. POSITION FRONT WHEELS FACING STRAIGHT AHEAD

  56. INSPECT SRS WARNING LIGHT

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