AIR CONDITIONING UNIT INSTALLATION

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.


  1. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Install the air conditioning unit with the nut.

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

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement with the No. 1 instrument panel spacer.

      A01GW4WE01
      Text in Illustration
      *1 Collar *2 "TORX" Bolt
      *3 No. 1 Instrument Panel Spacer - -

    2. Passenger side:

      Using a 12 mm hexagon wrench, tighten the 3 collars.

    3. Using a T40 "TORX" socket, install the 6 "TORX" bolts.

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

    4. Install the 6 instrument panel safety pad caps.

    5. Install the 9 bolts and 2 screws.

      A01GWH6E01
      Torque:
      for Bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for Bolt B
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    6. Connect the ground wires and install the junction block with the bolts and nuts.

      Torque:
      for Nut C
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for Bolt D
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    7. Attach the clamps and connectors and install the wire harness.

  3. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  4. CONNECT COOLER UNIT DRAIN HOSE


    1. A01H0DB

      Connect the 2 cooler unit drain hoses as shown in the illustration.

  5. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  6. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


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

    2. Install the bolt.

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

  7. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


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

    2. Install the screw.

  8. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  9. CONNECT HEATER WATER OUTLET HOSE


    1. A01GYNUE01
      Text in Illustration
      *1 Paint Mark
      *a 30° to 60°
      *b 75° to 105°

      Connect the heater water outlet hose and attach the clip.

      Tech Tips

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

  10. CONNECT HEATER WATER INLET HOSE

    Tech Tips

    Use the same procedure described for the water outlet hose.

  11. CONNECT COOLER REFRIGERANT LIQUID PIPE A


    1. Remove the attached vinyl tape from the pipe.

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

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring to the cooler refrigerant liquid pipe A.

    4. Connect the cooler refrigerant liquid pipe A.

    5. Turn the hook connector in the direction indicated by the arrow in the illustration.

    6. Install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

  12. CONNECT SUCTION TUBE SUB-ASSEMBLY B


    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 suction tube sub-assembly B.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring to the suction tube sub-assembly B.

    4. A01H0BBE02

      Connect the suction tube sub-assembly B.

    5. Turn the hook connector in the direction indicated by the arrow in the illustration.

    6. Install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

  13. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  14. ADD ENGINE COOLANT

    CAUTION:

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

    Tech Tips

    Before adding coolant, turn the A/C switch off.

    Total capacity
    11.1 liters (11.7 US qts, 9.8 Imp. qts)

    1. Tighten the radiator drain cock plug.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    3. Add TOYOTA Super Long Life Coolant (SLLC) into the radiator reservoir.

      Capacity
      5.0 liters (5.3 US qts, 4.4 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 consists of a combination of low phosphates and organic acids).

    4. Further add coolant into the reservoir until it reaches the FULL line.

    5. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level.

      If the coolant level is low, add coolant.

    6. Using a 6 mm hexagon wrench, install the vent plug.

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

    7. Bleed air from the cooling system.

      Tech Tips

      Before starting the engine to warm up the engine, turn the A/C switch off.


      1. Put the engine in inspection mode Click here.

      2. While idling the engine for approximately 10 minutes, make sure the coolant remains at the FULL line by adding coolant as necessary.

      3. A01H0PS

        After idling the engine for 10 minutes, add coolant until it reaches the B line.

        Capacity
        2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp. qts)
        Text in Illustration
        A01GYOB B Line

        Tech Tips

        The B line is the lower edge of the inner wall of the filler neck.

      4. Close the radiator reservoir cap, and run the engine at 1500 to 2000 rpm for 5 minutes.

        CAUTION:


        • Wear protective gloves.

        • Be careful as the radiator hose is hot.

        • Keep your hands away from the radiator fan.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 1 radiator hose by hand, and checking when the SLLC starts to flow inside the hose.

    8. Stop the engine and wait until the coolant cools down to ambient temperature.

    9. Check the coolant level.

      If the coolant level is below the FULL line, add coolant until it reaches the FULL line.

  15. ADD COMPRESSOR OIL


    1. When performing work on air conditioning parts, follow the oil guidelines below in order to protect the cooler compressor.

      Part and Condition Oil Level (cc) Work Procedure
      Compressor replacement -100 to -120 Drain oil from new compressor
      Condenser replacement 35 to 55 Fill oil into replacement part
      Evaporator replacement 40 to 60
      A/C pipe replacement High pressure 5 to 25
      Low pressure
      When discharging refrigerant gas quickly 30 to 50 While applying vacuum, use manifold gauge to fill oil from low pressure side valve

  16. CHARGE REFRIGERANT


    1. Perform vacuum purging using a vacuum pump or appropriate equipment.

    2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)
      A01GZBOE12
      Text in Illustration
      *a Sub-cool System *b High Pressure
      *c Refrigerant Amount *d Standard charge amount
      *e Charge additional 100 g (3.5 oz.) *f Point where bubbles disappear
      *g Mean value in proper range *h Overcharged
      Standard charge amount
      810 to 870 g (28.6 to 30.7 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 switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • The refrigerant amount should be checked by quantity (weight).

      Tech Tips

      Make sure 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 air conditioning system.

  17. WARM UP ENGINE


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

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

  18. CHECK FOR ENGINE COOLANT LEAKS

    CAUTION:

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

    Note

    Before each inspection, turn the A/C switch OFF.


    1. 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 engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

  19. CHECK FOR LEAKAGE OF REFRIGERANT


    1. After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Power switch off.

      • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).

      • Repeat the inspection 2 or 3 times.

      • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system (pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)).

    3. A01H0DZE40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Check for Leak

      Using a halogen leak detector, check for refrigerant leaks from the air conditioning system.

    4. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

    5. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

      Tech Tips

      When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

  20. CHECK SRS WARNING LIGHT

    Click here

  21. INSTALL BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman

      Attach the battery service hole cover LH with the clip and fastening tape.

  22. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Attach the 2 clips to install the deck trim side board LH.

  23. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  24. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI