AIR CONDITIONING UNIT INSTALLATION

INSTALL BLOWER ASSEMBLY

INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

1. Engage the 2 guides to temporary install the air conditioning amplifier assembly.

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

3. Connect the 3 connectors.

INSTALL ECU INTEGRATION BOX RH

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

   Torque:

   Nut

   5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

   Bolt

   7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

2. Connect each connector.

INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

INSTALL SEAT BELT CONTROL ECU (w/ Pre-crash Safety System)

1. Install the seat belt control ECU with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

2. Connect each connector.

INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

1. Connect the connector.

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

INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET

1. Engage the 2 guides 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.

INSTALL AUDIO AMPLIFIER COVER

1. Engage the 2 claws to temporarily install the audio amplifier cover.

2. Install the audio amplifier cover with the clip.

INSTALL TELEMATICS TRANSCEIVER WITH MAYDAY BATTERY (w/ Telematics Transceiver)

1. Connect each connector.

2. Engage the 2 guides to the vehicle body to temporarily install the telematics transceiver with mayday battery.

3. Install the telematics transceiver with back-up battery with the bolt.

INSTALL AUDIO AMPLIFIER COVER (w/ Telematics Transceiver)

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

INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

ADD ENGINE COOLANT (for 2AR-FE)

1. Tighten the radiator drain cock plug by hand.

2. 

   Text in Illustration

   *a

   Code Mark

   Check the code mark on the fan shroud.

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

   Specified capacity:

   Code Mark F and X	7.3 liters (7.7 US qts, 6.4 Imp. qts)
   Code Mark R	7.9 liters (8.3 US qts, 7.0 Imp. qts)

   Note

   Never use water as a substitute for engine coolant.

   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).

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

5. 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.

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 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 cooling 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.

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.

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.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

5. 

   Text in Illustration

   *a

   Code Mark

   Check the code mark on the fan shroud.

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

   Specified capacity:

   Code Mark I and V	9.2 liters (9.7 US qts, 8.1 Imp. qts)
   Code Mark W	9.4 liters (9.9 US qts, 8.3 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. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

8. 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.

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

10. 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 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 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.

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

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

INSPECT FOR COOLANT LEAK (for 2AR-FE)

INSPECT FOR COOLANT LEAK (for 2GR-FE)

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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).

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.

4. Remove the front bumper assembly Click here.

5. Remove the radiator side deflector RH Click here.

6. 

   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.

   

   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. 

   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. 

    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.