AIR CONDITIONING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Install the air conditioning unit assembly with the 3 nuts.

      A01EJMOE01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      Tighten the nuts in the order shown in the illustration to install the air conditioning unit assembly.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY


    1. Driver Side:


      1. Using a T40 "TORX" socket wrench, install the 2 "TORX" bolts.

        A01EK4JE01
        Text in Illustration
        *1 Collar *2 "TORX" Bolt
        *3 Bolt - -
        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      2. Install the bolt.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Passenger Side:


      1. Using a 12 mm hexagon wrench, install the 2 collars for adjustment.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Using a T40 "TORX" socket wrench, install the 2 "TORX" bolts.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    3. for LH side:


      1. Install the hole plug.

    4. for RH side:


      1. Install the hole plug.

    5. Install the 2 bolts to the engine compartment side.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    6. Install the instrument panel reinforcement assembly with air conditioning unit assembly with the nut.

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

    7. Connect the cooler drain hose.

    8. Install the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    9. Install the 2 nuts and screw.

    10. Engage each clamp.

    11. Connect the blower motor connector.

    12. Connect each connector.

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


    1. Install the screw.

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

    3. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    4. Engage each clamp.

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


    1. Install the screw.

    2. Install the No. 1 instrument panel brace sub-assembly with the 2 bolts and 2 nuts.

    3. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    4. Engage each clamp.

  5. INSTALL NO. 3 INSTRUMENT PANEL REINFORCEMENT


    1. Install the No. 3 instrument panel reinforcement with the 2 nuts.

    2. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    3. Engage the clamp.

  6. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. Engage the 4 claws to install the No. 6 heater to register duct assembly.

    2. Engage the clamp.

  7. INSTALL NO. 1 CONSOLE BOX DUCT


    1. A01EJH9

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

  8. INSTALL FLOOR CARPET BRACKET LH


    1. Install the floor carpet bracket LH with the 3 clips.

    2. Engage the 2 clamps.

  9. INSTALL REAR NO. 1 AIR DUCT


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

  10. INSTALL REAR NO. 2 AIR DUCT


    1. A01EL6P

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

  11. INSTALL FLOOR CARPET BRACKET RH


    1. Install the floor carpet bracket RH with the 3 clips.

  12. INSTALL REAR NO. 3 AIR DUCT


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

  13. INSTALL REAR NO. 4 AIR DUCT


    1. A01EJZ5

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

  14. INSTALL POWER STEERING ECU ASSEMBLY


    1. A01EJ63

      Engage the 4 wire harness clamps to the power steering ECU assembly.

    2. A01EL1O

      Install the power steering ECU assembly with the 3 nuts.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }
    3. A01EIRA

      Securely connect the connector to the power steering ECU assembly.

      Tech Tips

      Return the lock lever to its original position to connect the connector, and then securely push in the lock of the lock lever as shown in the illustration .

    4. A01EIYN

      Connect the 3 connectors to the power steering ECU assembly.

  15. INSTALL MAIN BODY ECU (DRIVER SIDE JUNCTION BLOCK ASSEMBLY)


    1. A01ELOW

      Engage the 2 claws to install the driver side junction block assembly.

    2. Connect the connectors to the back of the driver side junction block assembly.

    3. A01EMEI

      Install the driver side junction block assembly with the 3 nuts.

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

    4. Connect the connectors to the driver side junction block assembly.

  16. INSTALL 4WD CONTROL ECU (for 4WD)


    1. A01EIR4

      Install the ECU with the 2 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    2. A01EK3T

      Connect the connector.

  17. INSTALL POWER MANAGEMENT CONTROL ECU


    1. A01EL48

      Install the power management control ECU with the 2 nuts.

    2. Connect the 2 connectors.

  18. INSTALL TURN SIGNAL FLASHER ASSEMBLY


    1. A01ELOA

      Engage the clamp to install the turn signal flasher assembly.

    2. Connect the connector.

  19. INSTALL STEERING POST ASSEMBLY

    Click here

  20. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  21. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  22. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  23. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the pipe.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the air conditioning tube and accessory assembly.

  24. CONNECT SUCTION HOSE SUB-ASSEMBLY


    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 suction hose sub-assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the suction hose sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the suction hose sub-assembly.

    5. A01EKDY

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

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

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

  25. CONNECT INLET HEATER WATER HOSE


    1. Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.

  26. CONNECT OUTLET HEATER WATER HOSE


    1. Using pliers, grip the claws of the clip and slide the clip to connect the outlet heater water hose.

  27. INSTALL OUTER COWL TOP PANEL


    1. A01EL1AE01
      Text in Illustration
      *1 Bolt
      *2 Nut

      Install the outer cowl top panel with the 4 bolts and 4 nuts.

      Torque:
      Nut
      85 N*m  { 866 kgf*cm, 63 ft.*lbf }
      Bolt
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
    2. A01EIQY

      Engage the 2 wire harness clamps to the outer cowl top panel.

    3. A01EKSW

      Engage the 2 wire harness clamps to the outer cowl top panel and connect the connector (w/ Windshield Deicer).

  28. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  29. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

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

      Standard Capacity
      7.1 liters (7.5 US qts, 6.2 lmp. 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).

      Note

      Never use water as a substitute for engine coolant.

    3. A01EMHKE02
      Text in Illustration
      *1 Full Line

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

    4. 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.

    5. 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 No. 2 radiator hose by hand, and sensing vibrations 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 No. 1 and No. 2 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 cooling fans.

        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.

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

    7. Add engine coolant to the full line on the radiator reservoir.

  30. 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. A01EJTT

      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.

  31. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      450 to 550 g (15.9 to 19.4 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 with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      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.

  32. 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 switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  33. INSPECT FOR REFRIGERANT LEAK


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

    2. Carry out the test under the following conditions:


      • Turn the ignition switch off.

      • Secure good ventilation (the halogen 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 (4.0 to 6.0 kgf/cm2, 57 to 85 psi)

    3. A01EMP0E29
      Text in Illustration
      *1 Halogen Leak Detector

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

    4. A01EJA9E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      Bring the halogen 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 halogen leak detector sensor under the drain hose.

      • When bringing the halogen leak detector close to the drain hose, make sure that the halogen 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 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 perform the test.

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

  34. INITIALIZATION SERVO MOTOR


    1. Turn the ignition switch off.

    2. Connect the GTS to the DLC3.

    3. Turn the ignition switch to on.

    4. Press the A/C OFF switch.

    5. Turn the GTS on.

    6. Enter the following menus: Body Electrical / Air Conditioner / Utility / Servomotor Initialization.

    7. According to the GTS display, select the "Next" switch.

    8. According to the GTS display, select the "Next" switch.

      Tech Tips

      During initialization, the AUTO indicator illuminates. When initialization is complete, the indicator turns off.

    9. According to the GTS display, select the exit to finish the initialization.