AIR CONDITIONING UNIT INSTALLATION

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.

INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/o ECU Integration Box RH)

1. w/ ECU Integration Box RH:

   1. Engage the 2 claws and install the certification ECU (smart key ECU assembly).

2. w/o ECU Integration Box RH:

   1. Install the certification ECU (smart key ECU assembly) with the nut and bolt.

   2. Connect each connector.

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.

INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

1. Check that the ignition switch is off.

2. Check that the cable is disconnected from the negative (-) battery terminal.

   CAUTION:

   Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

3. Connect the airbag connector to the lower No. 1 instrument panel airbag assembly.

   

   Text in Illustration

   *1	Airbag Connector
   *2	Airbag Connector Lock

   Note

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

4. Push in the lock to install the airbag connector.

5. Temporarily install the lower No. 1 instrument panel airbag assembly with the 2 hooks.

6. Engage the 2 claws to install the DLC3.

7. Install the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   Confirm that the lower No. 1 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

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 }

INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers)

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

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.

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

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

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.

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.

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.

INSPECT FOR COOLANT LEAK (for 2AR-FE)

1. 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.

INSPECT FOR COOLANT LEAK (for 2GR-FE)

1. 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.

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)

   

   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.

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, 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 (3.9 to 5.9 kgf/cm², 57 to 85 psi)

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

   

   Text in Illustration

   *1	Halogen Leak Detector
   *a	Inspect for Leak

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

   

   Text in Illustration

   *1	Halogen Leak Detector
   *2	Drain Hose

   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.