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.

      A01HY6JE01
      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 TRANSPONDER KEY ECU ASSEMBLY (w/ Engine Immobiliser System)


    1. Connect the connector and install the transponder key ECU assembly.

  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    Note


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

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


    1. w/ Engine Immobiliser System:


      1. Engage the 2 guides and claw to connect the transponder key ECU assembly as shown in the illustration.

        A01HZURE01
        Text in Illustration
        *A w/ Engine Immobiliser System - -

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

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

      A01HZCNE01
      Text in Illustration
      *1 Movable Collar *2 Instrument Panel Reinforcement Assembly
      *a Vehicle Body *b Step 1
      *c Step 2 *d Step 3
      *e 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.

    4. Install the bolt.

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

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    6. A01HZG1

      Pass the drain cooler hose through the vehicle securely.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

    7. A01I1OME05

      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.

    8. Engage each clamp.

    9. Connect the connector.

    10. Connect the connector holder with the 2 nuts.

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

    11. Connect the earth wire with the bolt.

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

    12. Engage each clamp.

    13. Connect the 2 earth wires with the 2 bolts.

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

    14. Engage each clamp.

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

      A01I0RT
    16. A01I0CPE03
      Text in Illustration
      *a Retainer

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

    17. A01I1TPE01
      Text in Illustration
      *A w/ Smart Key System
      *1 Airbag Sensor Assembly

      Engage each clamp.

    18. Connect each connector.

    19. Connect the connector to the airbag sensor assembly as shown in the illustration.

      Note

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

    20. A01HZMD

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

    21. w/ Manual (SOS) Switch:


      1. Engage the clamp.

    22. for 10 Speakers:


      1. Engage the 3 clamps.

  4. INSTALL FRONT LOWER PANEL PACKING


    1. A01I0ZQ

      Install the 2 front lower panel packings.

  5. INSTALL INSTRUMENT PANEL SAFETY PAD CAP


    1. A01HXSJE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Install 5 new instrument panel safety pad caps.

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


    1. Install the screw and 2 nuts.

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

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

      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 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. Install the screw and 2 nuts.

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

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

      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.

  8. INSTALL ROOM TEMPERATURE SENSOR (COOLER THERMISTOR) (for Automatic Air Conditioning System)


    1. Connect the connector and cooler thermistor hose to install the room temperature sensor (cooler thermistor).

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


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

  10. INSTALL REAR NO. 3 AIR DUCT


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

  11. INSTALL FLOOR CARPET BRACKET LH


    1. Engage the 2 guides.

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

  12. INSTALL REAR NO. 4 AIR DUCT


    1. A01I1OY

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

  13. INSTALL FRONT FLOOR CARPET LH


    1. Engage each fastener and the guide to install the front floor carpet LH.

  14. CONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY


    1. A01HYXO

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

    2. Install the screw.

  15. INSTALL REAR NO. 1 AIR DUCT


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

  16. INSTALL FLOOR CARPET BRACKET RH


    1. Engage the 2 guides.

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

  17. INSTALL REAR NO. 2 AIR DUCT


    1. A01I24R

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

  18. INSTALL FRONT FLOOR CARPET RH


    1. Engage each fastener and the guide to install the front floor carpet RH.

  19. INSTALL FLOOR CARPET HOOK


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

    2. Engage the 6 guides.

  20. INSTALL REMOTE ENGINE STARTER ECU (w/ Remote Engine Starter System)


    1. Install the remote engine starter ECU with the nut.

    2. Connect the connector.

  21. INSTALL GLASS BREAKAGE SENSOR ECU (w/ Glass Breakage Sensor)


    1. Install the glass breakage sensor ECU with the nut.

    2. Connect the connector.

  22. 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.

  23. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/ Smart Key System)

    w/o ECU Integration Box RH: Click here

  24. INSTALL ECU INTEGRATION BOX RH (w/ 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.

  25. INSTALL STEERING POST ASSEMBLY

    Click here

  26. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  27. 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. Connect each connector and engage the clamp.

    4. Connect the ground wire with the bolt.

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

  28. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers)


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

  29. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Manual Seat)

    Click here

  30. INSTALL FRONT SEAT ASSEMBLY LH (for TMMK Made Power Seat)

    Click here

  31. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Manual Seat)

    Click here

  32. INSTALL FRONT SEAT ASSEMBLY LH (for SIA Made Power Seat)

    Click here

  33. 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.

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


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

  35. INSTALL FRONT SEAT ASSEMBLY RH (for TMMK Made Manual Seat)

    Tech Tips

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

  36. INSTALL FRONT SEAT ASSEMBLY RH (for TMMK Made Power Seat)

    Tech Tips

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

  37. INSTALL FRONT SEAT ASSEMBLY RH (for SIA Made Manual Seat)

    Tech Tips

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

  38. INSTALL FRONT SEAT ASSEMBLY RH (for SIA Made Power Seat)

    Tech Tips

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

  39. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.

    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 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surface free from dirt and foreign matter.

    4. Connect the air conditioner tube and accessory assembly.

  40. CONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made)


    1. Remove the vinyl tape from the suction hose sub-assembly.

    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 to the suction hose sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free from dirt and foreign matter.

    4. Connect the suction hose sub-assembly.

    5. A01HXNY

      Rotate the hook connector as shown in the illustration.

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

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

  41. CONNECT SUCTION PIPE SUB-ASSEMBLY (for SIA Made)


    1. Remove the vinyl tape from the suction pipe sub-assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surface free from dirt and foreign matter.

    4. Connect the suction pipe sub-assembly.

    5. A01HXNY

      Rotate the hook connector as shown in the illustration.

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

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

  42. CONNECT HEATER INLET WATER HOSE


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

  43. CONNECT HEATER OUTLET WATER HOSE


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

  44. 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.

  45. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  46. ADD ENGINE COOLANT (for 2AR-FE)


    1. Tighten the radiator drain cock plug by hand.

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

      Note

      Never use water as a substitute for engine coolant.

      Specified capacity
      7.3 liters (7.7 US qts, 6.4 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).

    3. Slowly pour coolant into the radiator reserve tank assembly 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. Install the radiator cap sub-assembly and reserve tank cap.

    6. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to the low setting.


      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 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 reserve tank assembly 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 reserve tank assembly 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 reserve tank assembly is filled to the full line.

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

    8. Add engine coolant to the full line on the radiator reserve tank assembly.

  47. ADD ENGINE COOLANT (for 2GR-FE)


    1. Tighten the radiator drain cock plug by hand.

    2. Close the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

    4. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the 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 }

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

      Specified capacity
      9.1 liters (9.6 US qts, 8.0 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).

    6. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line.

    7. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    8. Install the radiator cap sub-assembly and reserve tank cap.

    9. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to the low setting.


      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 outlet 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 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 fans.

        Note


        • Make sure that the radiator reserve tank assembly 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 reserve tank assembly 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 reserve tank assembly is filled to the full line.

    10. Stop the engine, and wait until the engine coolant cools down.

    11. Add engine coolant to the full line on the radiator reserve tank assembly.

  48. INSPECT FOR COOLANT LEAK (for 2AR-FE)

    Note

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


    1. A01I0PU

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

    2. Warm up the engine.

    3. 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.

  49. INSPECT FOR COOLANT LEAK (for 2GR-FE)

    CAUTION:

    Do not remove the radiator cap sub-assembly 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. A01HYQS

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

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 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.

  50. 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)
      A01HYRIE11
      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.

  51. 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).

  52. 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:


      • Ignition 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. A01HZSCE40
      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. A01HYW1E08
      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.

  53. INITIALIZATION SERVO MOTOR (for Automatic Air Conditioning System)

    Click here

  54. INITIALIZATION SERVO MOTOR (for Manual Air Conditioning System)

    Click here