AIR CONDITIONING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

      A01HVL1E01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

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

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    Note


    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.

    • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. Disengage the 3 guides and temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

      A01HTQG

    2. Install the instrument panel reinforcement assembly with the 3 bolts <A> and 2 new bolts <B>in the order shown in the illustration.

      A01HV9ME01
      Text in Illustration
      *1 Movable Collar *2 Body
      *3 Instrument Panel Reinforcement - -
      *a Step 1 *b Step 2
      *c Step 3 *d Step 4
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

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

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

    4. Install the bolt.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
    5. A01HUOGE01

      Install the 2 bolts.

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

      Note

      Tighten the bolts in the order shown in the illustration.

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

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

    7. Install the 2 bolts.

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

    8. Engage each clamp.

    9. Connect the connector.

    10. Install the 2 nuts and connect the connector holder.

    11. Install the bolt and connect the earth wire.

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

    12. Engage each clamp.

    13. Connect the connector.

    14. Install the 2 bolts and connect the 2 earth wires.

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

    15. Engage each clamp.

    16. A01HVQY

      Pass the drain cooler hose through the vehicle securely.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

    17. Engage each clamp.

    18. Connect the connector.

    19. Engage each clamp.

    20. Engage the claw to connect the airbag connector as shown in the illustration.

      A01HV2V
    21. A01HTRDE01
      Text in Illustration
      *1 Retainer

      Engage the 2 claws to lock the retainer as shown in the illustration.

    22. Connect the connector.

    23. Install the bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

    24. Install the shift lever support with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    25. Check that the park/neutral position switch and the shift lever are in N.

    26. A01HW9RE03

      Install the lower shift lever assembly with the 4 bolts in the order shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    27. A01HSD5E03
      Text in Illustration
      *1 Slider
      *2 Lock Piece
      *a Slide
      *b Pull

      Slide the slider of the transmission control cable assembly in the direction indicated by the arrow and pull the lock piece outward.

    28. A01HV60E01
      Text in Illustration
      *1 Lock Piece

      Install the end of the transmission control cable assembly to the lower shift lever assembly.

      Note


      • Check that the lock piece is pulled up.

      • Install the cable end all the way to the base of the pin.

    29. Push the lock piece into the adjuster case.

      Note


      • Check that the park/neutral position switch and the shift lever are in neutral.

      • Securely push in the lock piece until the slider lock is engaged.

    30. A01HSD8E01
      Text in Illustration
      *1 Center Airbag Sensor Connector

      Connect each connector.

    31. Engage the 3 clamps.

    32. Connect the center airbag sensor connectors to the center airbag sensor assembly as shown in the illustration.

      Note

      When connecting any airbag connector, take care not to damage the airbag wire harness.

    33. A01HW5Z

      Engage the 3 claws to close the 3 clamps as shown in the illustration.

  3. INSTALL FRONT LOWER PANEL PACKING


    1. A01HVAB

      Install the 2 front lower panel packings shown in the illustration.

  4. INSTALL INSTRUMENT PANEL SAFETY PAD CAP


    1. A01HSGEE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Install 5 new instrument panel safety pad caps.

  5. 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.

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

    3. Connect the earth wire with the bolt.

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

    4. Engage each clamp.

    5. Connect the connector.

  6. INSTALL INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. Install the screw.

    2. Install the instrument panel to cowl brace sub-assembly with the bolt and 2 nuts.

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

    3. Connect the earth wire with the bolt.

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

    4. Engage each clamp.

    5. Connect each connector.

  7. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct)


    1. Install the No. 1 console box duct with the clip.

  8. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET


    1. Install the No. 1 console mounting bracket with the screw.

  9. INSTALL REAR NO. 3 AIR DUCT


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

  10. INSTALL FLOOR CARPET BRACKET LH


    1. Engage the 2 guides.

    2. Install the floor carpet bracket LH with the 2 clips.

  11. INSTALL REAR NO. 4 AIR DUCT


    1. A01HVQG

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

    2. A01HUSO

      Engage the guide to install the floor carpet to the original position as shown in the illustration.

  12. CONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY


    1. A01HVC2

      Engage the guide to connect the fuel lid lock open lever sub-assembly as shown in the illustration.

    2. Install the screw.

  13. INSTALL REAR NO. 1 AIR DUCT


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

  14. INSTALL FLOOR CARPET BRACKET RH


    1. Engage the 2 guides.

    2. Install the floor carpet bracket RH with the 2 clips.

  15. INSTALL REAR NO. 2 AIR DUCT


    1. A01HW08

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

    2. A01HUQA

      Engage the guide to install the floor carpet to the original position as shown in the illustration.

  16. INSTALL FLOOR CARPET HOOK


    1. Engage the 6 claws to install the 6 floor carpet hooks.

    2. Engage the 6 guides.

  17. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. Engage the 2 guides.

    2. Install the air conditioning amplifier assembly with the 2 screws.

    3. Connect each connector.

  18. INSTALL ECU INTEGRATION BOX RH


    1. Install the ECU integration box RH with the 2 nuts and bolt.

      Torque:
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Engage the clamp.

    3. Connect each connector.

  19. INSTALL VEHICLE APPROACHING SPEAKER CONTROLLER


    1. Engage the guide.

    2. Install the nut to install the vehicle approaching speaker controller.

      Torque:
      6.1 N*m  { 62 kgf*cm, 54 in.*lbf }

    3. Connect the connector.

  20. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


    1. A01HU29

      Engage the claw to connect the connector as shown in the illustration.

      Note

      Be sure to engage the connector securely.

    2. A01HVO1

      Engage the claw to lock the connector lock as shown in the illustration.

    3. A01HVOS

      Engage the claw to connect the connector as shown in the illustration.

      Note

      Be sure to engage the connector securely.

    4. Install the instrument panel junction block assembly with the bolt and 2 nuts.

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

    5. Connect each connector.

      Note

      Be sure to engage each connector securely.

  21. INSTALL POWER MANAGEMENT CONTROL ECU

    Click here

  22. INSTALL STEERING POST ASSEMBLY

    Click here

  23. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  24. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers)


    1. Engage the 2 guides to the vehicle body to temporarily install the stereo component amplifier assembly with bracket.

    2. Install the stereo component amplifier assembly with bracket with the bolt.

    3. Engage the clamp.

    4. Connect each connector.

    5. Connect the ground wire with the bolt.

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

  25. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers)


    1. Install the audio amplifier cover with the 2 clips.

  26. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)

    Click here

  27. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)

    Click here

  28. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch)


    1. Engage the 2 guides to the vehicle body to temporarily install the DCM (telematics transceiver) with back-up battery.

    2. Install the DCM (telematics transceiver) with back-up battery with the bolt.

    3. Connect each connector.

    4. Engage the 3 clamps.

  29. INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch)


    1. Install the audio amplifier cover with the 2 clips.

  30. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)

    Tech Tips

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

  31. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)

    Tech Tips

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

  32. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the pipe.

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

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring to the air conditioner tube and accessory assembly.

    4. Install the air conditioner tube and accessory assembly.

  33. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the 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 11 or equivalent

    3. Connect the O-ring to the suction hose sub-assembly.

    4. Connect the suction hose sub-assembly.

    5. A01HTLW

      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 }

  34. CONNECT HEATER INLET WATER HOSE


    1. Install the heater inlet water hose and attach the clip.

  35. CONNECT HEATER OUTLET WATER HOSE


    1. Install the heater outlet water hose and attach the clip.

  36. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  38. INSPECT FOR COOLANT LEAK (for Engine)

    Note

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


    1. A01HU5A

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

    2. Put the engine in inspection mode Click here.

    3. Warm up the engine.

    4. Using a 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.

  39. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine)


    1. Check that the engine coolant level is between the low and full lines when the engine is cold.

      If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the full line.

      Note

      Do not substitute plain water for engine coolant.

  40. CHARGE AIR CONDITIONING SYSTEM WITH 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)
      A01HSHEE11
      Text in Illustration
      *a Sub-cool System *b High Pressure
      *c Refrigerant Amount *d Standard charge amount
      *e Charge additional 100g (3.5oz.) *f Point where bubbles disappear
      *g Mean value in proper range *h Overcharged
      Standard charge amount
      480 to 580g (16.9 to 20.4oz.)
      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).

      • The graph above is shown for reference only. This vehicle is not equipped with a 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 air conditioning system.

  41. WARM UP COMPRESSOR


    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).

  42. INSPECT FOR REFRIGERANT LEAK


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

    2. Carry out the test under the following conditions:


      • Turn the 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 (4.0 to 6.0 kgf/cm2, 57 to 85 psi)

    3. A01HUA4E40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Inspect for Leak

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

    4. A01HSWYE08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

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

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit 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 checking for leaks.

    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 check for a leak.

    6. 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.

  43. INITIALIZATION SERVO MOTOR

    Click here