AIR CONDITIONING UNIT (for TMC, TMMR Made) INSTALLATION


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


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

      B000KSOE01
      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 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. Engage the 3 guides to temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

      B000KF2

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

      B000K4PE01
      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 instrument panel reinforcement assembly.

    3. Pass the drain cooler hose through the vehicle securely.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

    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. B000KYXE05

      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.

    7. Engage each clamp.

    8. Connect the connector.

    9. Connect the connector holder with the 2 nuts.

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

    10. Connect the earth wire with the bolt.

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

    11. Engage each clamp.

    12. for Power Tilt and Power Telescopic Steering Column:


      1. Connect the protector with the nut.

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

    13. Engage each clamp.

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

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

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

      B000M6Z
    16. B000NOAE03
      Text in Illustration
      *a Retainer

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

    17. w/ PTC Heater:


      1. Connect the connector.

      2. Install the bolt.

        Torque:
        20 N*m  { 199 kgf*cm, 14 in.*lbf }
      3. B000MFZ

        Install the shift lever support with the 4 bolts in the sequence shown in the illustration.

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

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

      5. B000IHJE01

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

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      6. B000L6AE05
        Text in Illustration
        *a Slide
        *b Pull
        *c Slider
        *d Lock Piece

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

      7. B000JJRE03
        Text in Illustration
        *a Lock Piece

        Install the transmission control cable end 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.

      8. 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.

    18. B000IL5E01
      Text in Illustration
      *A w/ Smart Entry and Start System
      *1 Airbag Sensor Assembly

      Engage each clamp.

    19. Connect each connector.

    20. 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.

    21. B000K54

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

    22. for 10 Speakers:


      1. Engage the 3 clamps.

  3. INSTALL FRONT LOWER PANEL PACKING


    1. B000L6D

      Install the 2 front lower panel packings.

  4. INSTALL INSTRUMENT PANEL SAFETY PAD CAP


    1. B000NPZE02
      Text in Illustration
      *A for Driver Side
      *B for Passenger Side

      Install 5 new instrument panel safety pad caps.

  5. 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 the connector.

  6. 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 each connector.

  7. INSTALL ROOM TEMPERATURE SENSOR (COOLER THERMISTOR)


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

  8. INSTALL NO. 1 CONSOLE BOX DUCT


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

  9. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET (w/ PTC Heater)


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

  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. B000MLK

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

    2. B000I6E

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

  13. CONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY


    1. B000JQY

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

    2. Install the screw.

  14. INSTALL REAR NO. 1 AIR DUCT


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

  15. INSTALL FLOOR CARPET BRACKET RH


    1. Engage the 2 guides.

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

  16. INSTALL REAR NO. 2 AIR DUCT


    1. B000M58

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

    2. B000H31

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

  17. INSTALL FLOOR CARPET HOOK


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

    2. Engage the 6 guides.

  18. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)


    1. Install the windshield wiper relay assembly with the nut.

    2. Connect the connector.

  19. 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.

  20. INSTALL ECU INTEGRATION BOX RH (w/ ECU Integration Box RH)


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

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

    2. Connect each connector.

  21. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for LHD)


    1. B000HN1

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

      Note

      Be sure to engage the connector securely.

    2. B000J0G

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

    3. B000MN3

      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.

  22. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for RHD)


    1. B000HN1

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

      Note

      Be sure to engage the connector securely.

    2. B000J0G

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

    3. B000MN3

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

      Note

      Be sure to engage the connector securely.

    4. Engage the claw to install the wiring harness clamp bracket.

    5. Install the nut.

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

    6. Install the instrument panel junction block assembly with the bolt and nut.

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

    7. Connect each connector.

      Note

      Be sure to engage each connector securely.

  23. INSTALL STEERING POST ASSEMBLY

    Click here

  24. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  25. 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 }

  26. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers)


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

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

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure as for the LH side.

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

    Tech Tips

    Use the same procedure as for the LH side.

  31. 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 the fitting surface of the air conditioning tube and accessory assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

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

    4. Connect the air conditioner tube and accessory assembly.

  32. CONNECT SUCTION PIPE SUB-ASSEMBLY


    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. B000N5W

      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 }

  33. CONNECT HEATER INLET WATER HOSE


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

  34. CONNECT HEATER OUTLET WATER HOSE


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

  35. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    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.

    3. w/ Windshield Deicer System:


      1. Connect the connector.

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

    4. w/ Heated Windshield Defroster System:


      1. Connect the 2 connectors.

      2. Engage the 4 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

  36. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    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. ADD ENGINE COOLANT (for 2AR-FE)


    1. Tighten the radiator drain cock plug by hand.

    2. B000J9RE01
      Text in Illustration
      *a Code Mark

      Slowly fill the radiator assembly with engine coolant.

      Specified Capacity
      Code Mark "M" 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Code Mark "G" 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Code Mark "Z" 7.3 liters (7.7 US qts, 6.4 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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. Remove the reserve tank cap.

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

    5. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

      If the engine coolant level is low, add engine coolant.

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

    7. 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 engine 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 No. 2 radiator hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the cooling system.

        CAUTION:

        When squeezing the No. 1 radiator hose and No. 2 radiator hose:


        • Wear protective gloves.

        • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

        • Keep your hands away from the fan and No. 2 fan.

        Note


        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

        • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

        • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

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

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

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


    1. Tighten the radiator drain cock plug by hand.

    2. Close the cylinder block drain cock plug (for Bank 1).

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

    3. Close the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

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

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

    5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until engine 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 }
    6. B000L9EE01
      Text in Illustration
      *a Code Mark

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

      Specified capacity
      Code Mark "K" 8.8 liters (9.3 US qts, 7.7 Imp. qts)
      Code Mark "J" 8.9 liters (9.4 US qts, 7.8 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 is a combination of low phosphates and organic acids).

    7. Remove the reserve tank cap.

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

    9. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the engine coolant.

      If the engine coolant level is low, add engine coolant.

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

    11. 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 engine 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 No. 2 radiator 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 No. 1 and No. 2 radiator hoses:


        • Wear protective gloves.

        • Be careful as the No. 1 and No. 2 radiator hoses are hot.

        • Keep your hands away from the fans.

        Note


        • Make sure that the radiator reserve tank assembly still has some engine 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 engine coolant, the engine may overheat or be seriously damaged.

        • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

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

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

  40. ADD ENGINE COOLANT (for 6AR-FSE)


    1. Tighten the radiator drain cock plug by hand.

    2. Slowly fill the radiator assembly with engine coolant.

      Specified Capacity
      7.3 liters (7.7 US qts, 6.4 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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. Remove the reserve tank cap.

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

    5. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

      If the engine coolant level is low, add engine coolant.

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

    7. 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 engine 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 No. 2 radiator hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the cooling system.

        CAUTION:

        When squeezing the No. 1 radiator hose and No. 2 radiator hose:


        • Wear protective gloves.

        • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

        • Keep your hands away from the fan and No. 2 fan.

        Note


        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

        • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

        • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

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

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

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

    Note

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


    1. B000HO1

      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.

  42. 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. B000KGC

      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.

  43. INSPECT FOR COOLANT LEAK (for 6AR-FSE)


    1. Remove the radiator cap sub-assembly.

    2. B000HO1E01
      Text in Illustration
      *a Radiator Cap Tester

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

    3. Warm up the engine.

    4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.


      • If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.

      • If there are no signs of external engine coolant leaks, check the heater core, cylinder block sub-assembly and cylinder head sub- assembly.

    5. Remove the radiator cap tester.

    6. Install the radiator cap sub-assembly.

  44. 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)
      B000JWVE14
      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
      *i +/-50 g (+/-1.76 oz) - -
      Standard charge amount
      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 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

      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.

  45. 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).

  46. INSPECT FOR REFRIGERANT LEAK


    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:


      • Turn the engine switch off.

      • 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)

      • Ensure 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.

    3. Remove the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

    4. Remove the front bumper assembly Click here.

    5. Remove the radiator side deflector RH Click here.

    6. B000HJJE01
      Text in Illustration
      *a Check for leaks
      *b Halogen Leak Detector Sensor
      *c

      Distance between Sensor and Joint to be Checked:

      10 mm or less
      *d

      Halogen Leak Detector Sensor Moving Speed:

      25 to 50 mm/sec.

      How to check for refrigerant leaks in pipe joints:

      Note

      Gas leaking from a joint can be dissipated by even the slightest breeze. Move the halogen leak detector sensor 360° around each joint instead of keeping it in one spot when checking.

    7. Using a halogen leak detector, check for refrigerant leaks at the pipe joints shown in the illustration.

      B000NHME01
      Text in Illustration
      *a Area to be Checked *b Service Valve (High)
      *c Service Valve (Low) *d Pipe Joint
      *e Air Conditioner Pressure Sensor Joint *f Cooler Expansion Valve Joint
      *g Condenser Joint (Inlet) *h Condenser Joint (Outlet)
      *i Compressor Joint (Inlet) *j Compressor Joint (Outlet)

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

      • Disconnect the pressure sensor connector and leave it for approximately 20 minutes.

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

      Standard
      There are no refrigerant leaks from the joints.

      If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

    8. B000MNOE01
      Text in Illustration
      *1 Drain Cooler Hose
      *a Halogen Leak Detector

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

      Note

      Keep water away from the halogen leak detector to prevent malfunction.

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

      • When bringing the halogen leak detector sensor close to the drain cooler 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.

      Standard
      Refrigerant is not leaking from the drain cooler hose.

      If refrigerant is leaking, check for refrigerant leaks from the No. 1 cooler evaporator sub-assembly.

    9. Remove the blower motor with fan sub-assembly Click here.

    10. B000IAWE01
      Text in Illustration
      *1 No. 1 Cooler Evaporator Sub-assembly
      *a Halogen Leak Detector

      Insert the halogen leak detector sensor into the air conditioning unit assembly, bring the sensor close to the No. 1 cooler evaporator sub-assembly and check for refrigerant leaks.

      Tech Tips

      After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

      Standard
      Refrigerant is not leaking from the No. 1 cooler evaporator sub-assembly.

      If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

    11. Install the blower motor with fan sub-assembly Click here.

    12. Install the radiator side deflector RH Click here.

    13. Install the front bumper assembly Click here.

    14. Install the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

  47. INITIALIZATION SERVO MOTOR

    Click here