AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

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

    Note


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

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


    1. Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

      B004QKEC01
      B004PI4 Install in this Direction - -

    2. Connect each connector.

    3. Install the 4 bolts (A).

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    4. Connect the parking brake pedal assembly with the bolt (B).

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

    5. Temporarily install the nut.

    6. Install the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    7. Connect the drain cooler hose.

    8. for LHD:


      1. Engage each clamp.

      2. Connect the relay block assembly with the bolt.

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

      3. Connect the 3 earth wires with the 3 bolts.

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

      4. Connect each connector.

    9. for RHD:


      1. Engage each clamp.

      2. Connect the relay block assembly with the bolt.

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

      3. Connect the 3 earth wires with the 3 bolts.

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

      4. Connect each connector.

  3. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. Engage the 6 claws to install the lower defroster nozzle assembly.

  4. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    Click here

  5. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

      Torque:
      Bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. for LHD:


      1. Engage the clamp and 2 claws to connect the DLC3 connector.

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


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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. Engage each clamp.

    4. B004QOX

      Install the front floor mat to its original position as shown in the illustration.

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


    1. Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. w/ PTC Heater:


      1. Connect the earth wire with the bolt.

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

    4. Connect the earth wire with the bolt.

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

    5. Engage each clamp.

    6. B004Q4E

      Install the front floor mat to its original position as shown in the illustration.

  8. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. for LHD:


      1. Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.

        B004Q2UC01
        B004PRK Bolt B004P9H Screw
        B004PZY Nut - -
        Torque:
        Bolt
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
        Nut
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

        Note

        Tighten the bolts, screws and nut in the order shown in the illustration.

    2. for RHD:


      1. Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.

        B004QL7C02
        B004PRK Bolt B004P9H Screw
        B004PZY Nut - -
        Torque:
        Bolt
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
        Nut
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

        Note

        Tighten the bolts, screws and nut in the order shown in the illustration.

  9. INSTALL NO. 3 DASH PANEL INSULATOR PAD


    1. B004OKT

      Install the No. 3 dash panel insulator pad with 2 new clips as shown in the illustration.

  10. INSTALL REAR NO. 1 AIR DUCT


    1. Engage the 4 claws to install the rear No. 1 air duct.

  11. INSTALL REAR NO. 4 AIR DUCT


    1. Engage the 2 claws to install the rear No. 4 air duct.

  12. INSTALL REAR NO. 5 AIR DUCT


    1. B004QVSC01
      B004PI4 Install in this Direction

      Engage the 2 claws to install the rear No. 5 air duct as shown in the illustration.

    2. B004QYQ

      Install the front floor carpet assembly to its original position as shown in the illustration.

    3. Engage the 2 guides.

    4. Install the 2 front floor carpet clips.

  13. INSTALL REAR NO. 2 AIR DUCT


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

  14. INSTALL REAR NO. 3 AIR DUCT


    1. B004P0FC01
      B004PI4 Install in this Direction

      Engage the 2 claws to install the rear No. 3 air duct as shown in the illustration.

    2. B004Q9J

      Install the front floor carpet assembly to its original position as shown in the illustration.

    3. Engage the 2 guides.

    4. Install the 2 front floor carpet clips.

  15. INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. B004PC7C01
      B004PI4 Install in this Direction

      Engage the guide and claw to install the front floor caution plate cover as shown in the illustration.

  16. INSTALL FRONT NO. 2 CONSOLE BOX INSERT


    1. B004QTWC01
      B004PI4 Install in this Direction

      Engage the guide as shown in the illustration.

    2. B004Q79C01
      B004PI4 Install in this Direction

      Engage the claw and clip to install the front No. 2 console box insert as shown in the illustration.

  17. INSTALL FRONT NO. 1 CONSOLE BOX INSERT


    1. B004QCMC01
      B004PI4 Install in this Direction

      Engage the guide as shown in the illustration.

    2. B004R18C01
      B004PI4 Install in this Direction

      Engage the claw and clip to install the front No. 1 console box insert as shown in the illustration.

  18. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.

  19. INSTALL SHIFT LOCK CONTROL UNIT ASSEMBLY

    Click here

  20. INSTALL TELEMATICS TRANSCEIVER WITH ANTENNA CORD (w/ Telematics Transceiver)

    Click here

  21. INSTALL ECU INTEGRATION BOX LH (for RHD)

    Click here

  22. INSTALL ECU INTEGRATION BOX RH (for LHD)

    Click here

  23. INSTALL DOUBLE LOCK DOOR CONTROL RELAY ASSEMBLY (w/ Double Locking System)

    Click here

  24. INSTALL CLEARANCE WARNING ECU ASSEMBLY (w/ TOYOTA Parking Assist-sensor System)

    Click here

  25. INSTALL NO. 2 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System)

    Click here

  26. INSTALL NO. 1 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System)

    Click here

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

    Click here

  28. INSTALL DRIVING SUPPORT ECU ASSEMBLY (w/ Toyota Safety Sense P)

    Click here

  29. INSTALL SKID CONTROL BUZZER (w/ Toyota Safety Sense P)

    Click here

  30. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  31. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  32. INSTALL FRONT SEAT ASSEMBLY LH

    for Manual seat:

    Click here

    for Power seat:

    Click here

  33. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  34. 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 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.

      Note

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

    4. Connect the air conditioner tube and accessory assembly.

  35. 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 11 or equivalent

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

      Note

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

    4. Connect the suction pipe sub-assembly.

    5. B004PKZ

      Rotate the hook connector as shown in the illustration.

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

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

  36. CONNECT INLET HEATER WATER HOSE A


    1. w/o Exhaust Heat Recirculation System:


      1. B004Q1SC01
        *a View A
        *b Marking (Brown)
        *c Clip Installation Angle (60°)

        Connect the inlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.

        Note

        Do not apply excessive force to the inlet heater water hose A.

    2. w/ Exhaust Heat Recirculation System:


      1. B004P90C01
        *a View A
        *b Marking (Blue)
        *c Clip Installation Angle (60°)

        Connect the inlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.

        Note

        Do not apply excessive force to the inlet heater water hose A.

  37. CONNECT OUTLET HEATER WATER HOSE A (w/o Exhaust Heat Recirculation System)


    1. B004PEDC01
      *a View A
      *b Marking (Red)
      *c Clip Installation Angle (60°)

      Connect the outlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the outlet heater water hose A.

  38. CONNECT WATER PIPE AND HOSE SUB-ASSEMBLY A (w/ Exhaust Heat Recirculation System)


    1. B004PPSC01
      *a View A
      *b Marking (Green)
      *c Clip Installation Angle (60°)

      Connect the water pipe and hose sub-assembly A with the marking facing up and engage the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the water pipe and hose sub-assembly A.

  39. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  40. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  41. INSTALL WATER GUARD PLATE LH

    Click here

  42. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  43. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  44. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  45. ADD ENGINE COOLANT (for Engine)

    Click here

  46. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  47. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  48. WARM UP COMPRESSOR

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  49. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a (R134a):

    Click here

    for HFO-1234yf (R1234yf):

    Click here

  50. INITIALIZATION SERVO MOTOR

    Click here