FRONT AIR CONDITIONING UNIT INSTALLATION

INSTALL AIR CONDITIONING UNIT
1. Install the air conditioning unit with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
  
  Note
  
  Be sure to support the air conditioning unit when installing it because failure to do so may cause the bracket to be damaged.
2. Connect the cooler drain hose.
3. Connect the connector.
4. Engage each clamp.
INSTALL INSTRUMENT PANEL REINFORCEMENT
1. Install the instrument panel reinforcement with the 7 bolts <A>.
2. Install the bolt <B>.
  
  Torque:
  
  <B>
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
3. Install the 3 bolts <C>.
  
  Torque:
  
  <C>
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
  
  Note
  
  Tighten the bolts to the instrument panel reinforcement in the order shown in the illustration.
4. Engage the 2 junction blocks and install the 2 bolts and 3 nuts.
5. Engage the clamp.
INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
1. Install the 2 nuts.
2. Install the 3 bolts.
3. Install the No. 1 instrument panel brace sub-assembly with the 2 screws.
4. Install the clip.
5. Engage each clamp.
6. Connect the earth wire with the bolt.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
7. Engage each clamp.
8. Install the 2 nuts.
9. Connect the connector.
10. Connect the 2 earth wires with the 2 bolts.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
INSTALL NO. 2 INSTRUMENT PANEL TO COWL BRACE
1. Install the nut.
2. Install the No. 2 instrument panel to cowl brace with the bolt.
INSTALL ANTENNA CORD SUB-ASSEMBLY (for RHD)
1. Connect the 2 connectors and install the antenna cord sub-assembly with the bolt.
2. Engage the 9 clamps.
INSTALL ANTENNA CORD SUB-ASSEMBLY (for LHD)
1. w/o Front Center Speaker:
  1. Connect the 2 connectors and install the antenna cord sub-assembly with the bolt.
  2. Engage the 8 clamps.
2. w/ Front Center Speaker:
  1. Connect the connector and install the antenna cord sub-assembly with the bolt.
  2. Engage the 7 clamps.
INSTALL CLEARANCE WARNING BUZZER (for RHD)
1. Engage the clamp to install the clearance warning buzzer.
2. Connect the connector.
INSTALL CLEARANCE WARNING BUZZER (for LHD)
1. Engage the clamp to install the clearance warning buzzer.
2. Connect the connector.
INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (for RHD)
1. Install the windshield wiper relay assembly with the bolt.
2. Connect the connector.
INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (for LHD)
1. Install the windshield wiper relay assembly with the bolt.
2. Connect the connector.
INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
1. Install the air conditioning amplifier assembly with the 2 screws.
2. Connect each connector.
3. Engage the clamp.
INSTALL REAR NO. 3 AIR DUCT
1. Engage the 2 claws to install the rear No. 3 air duct.
INSTALL REAR NO. 4 AIR DUCT
1. Engage the 2 claws to install the rear No. 4 air duct.
2. Install the clip.
INSTALL REAR NO. 1 AIR DUCT
1. Engage the 2 claws to install the rear No. 1 air duct.
INSTALL REAR NO. 2 AIR DUCT
1. Engage the 2 claws to install the rear No. 2 air duct.
2. Install the clip.
INSTALL DASH PANEL INSULATOR PAD LH
1. Install the dash panel insulator pad LH.
INSTALL DASH PANEL INSULATOR PAD RH
1. Install the dash panel insulator pad RH.
INSTALL FRONT FLOOR MAT PAD
1. Install the front floor mat pad.
2. Install the floor carpet to the original position.
INSTALL STEERING COLUMN ASSEMBLY

Click here
INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

Click here
INSTALL FRONT SEAT ASSEMBLY (for Manual Seat Type RH Side)

Click here
INSTALL FRONT SEAT ASSEMBLY (for Driver Side Power Seat)

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INSTALL FRONT SEAT ASSEMBLY (for Manual Seat Type LH Side)

Tech Tips

Use the same procedure for the LH side and RH side Click here
INSTALL FRONT SEAT ASSEMBLY (for Passenger Side Power Seat)

Click here
CONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Remove the attached vinyl tape from the pipe.
2. Sufficiently apply compressor oil to a new O-ring and fitting surface of the No. 2 air conditioning tube and accessory assembly.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the No. 2 air conditioning tube and accessory assembly.
  
  Note
  
  Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.
4. Install the No. 2 air conditioning tube and accessory assembly.
CONNECT NO. 1 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Remove the attached vinyl tape from the pipe.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 air conditioning tube and accessory assembly.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the No. 1 air conditioning tube and accessory assembly.
  
  Note
  
  Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.
4. Install the No. 1 air conditioning tube and accessory assembly.
5. Move the hook connector in the direction indicated by the arrow in the illustration.
6. Insert the pipe joint into the fitting hole securely and tighten the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
CONNECT HEATER WATER OUTLET HOSE A
1. Using pliers, grip the claws of the clip and slide the clip to connect the heater water outlet hose A.
CONNECT HEATER WATER INLET HOSE A
1. Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose A.
ADD ENGINE COOLANT (for 2AZ-FE)
1. Tighten the radiator drain cock plug by hand.
2. Add engine coolant.
  
  Standard capacity
  
  8.6 liters (9.1 US qts, 7.6 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 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).
  - 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.
3. Text in Illustration
  
  *a B Line
  
  Continue adding engine coolant until it reaches the B line. (*1)
4. Install the reserve tank cap. (*2)
5. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes. (*3)
  CAUTION:
  - 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 radiator reserve tank runs out of engine coolant just after the engine is started, stop the engine immediately, wait until the engine coolant has cooled down, and then add engine coolant.
  - Make sure that the radiator reserve tank 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.
6. Stop the engine and wait until the engine coolant cools down. (*4)
7. Text in Illustration
  
  *a Full Line
  
  *b Low Line
  
  Check that the engine coolant level is between the full line and low line. (*5)
  Tech Tips
  - If the engine coolant level is below the low line, remove the reserve tank cap and repeat steps from (*1) to (*5).
  - If the engine coolant level is above the full line, drain engine coolant so that the engine coolant level is between the full line and low line.
ADD ENGINE COOLANT (for 2GR-FE)
1. Tighten the radiator drain cock plug by hand.
2. Tighten the cylinder block drain cock plug (for Bank 1).
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
3. Tighten 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.
5. Add engine coolant.
  
  Standard Capacity
  
  10.6 liters (11.2 US qts, 9.3 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 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).
  - 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. Add engine coolant to the radiator reserve tank until engine coolant overflows from the air drain cock plug hole. Then tighten the air drain cock plug.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
7. Text in Illustration
  
  *a B Line
  
  Continue adding engine coolant until it reaches the B line. (*1)
8. Install the reserve tank cap. (*2)
9. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes. (*3)
  CAUTION:
  - 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 radiator reserve tank runs out of engine coolant just after the engine is started, stop the engine immediately, wait until the engine coolant has cooled down, and then add engine coolant.
  - Make sure that the radiator reserve tank 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.
10. Stop the engine and wait until the engine coolant cools down. (*4)
11. Text in Illustration
  
  *a Full Line
  
  *b Low Line
  
  Check that the engine coolant level is between the full line and low line. (*5)
  Tech Tips
  - If the engine coolant level is below the low line, remove the reserve tank cap and repeat steps from (*1) to (*5).
  - If the engine coolant level is above the full line, drain engine coolant so that the engine coolant level is between the full line and low line.
INSPECT FOR COOLANT LEAK (for 2AZ-FE)
1. Remove the reserve tank cap.
  
  CAUTION:
  
  Do not remove the reserve tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
2. Text in Illustration
  
  *1 Radiator Cap Tester
  
  Fill the radiator and radiator reserve tank with coolant, and then attach 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 and water pump for leaks.
  
  If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
5. Reinstall the reserve tank cap.
INSPECT FOR COOLANT LEAK (for 2GR-FE)
1. Remove the radiator reservoir cap.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
2. Fill the radiator and reservoir with coolant, and then attach 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 and water pump for leaks.
  
  If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
5. Reinstall the radiator reservoir cap.

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

Standard capacity
8.6 liters (9.1 US qts, 7.6 Imp. qts)

Text in Illustration
*a	B Line

Text in Illustration
*a	Full Line
*b	Low Line

Standard Capacity
10.6 liters (11.2 US qts, 9.3 Imp.qts)

Text in Illustration
*a	B Line

Text in Illustration
*a	Full Line
*b	Low Line

Text in Illustration
*1	Radiator Cap Tester

CHARGE WITH REFRIGERANT

Perform vacuum purging using a vacuum pump.

Charge with refrigerant HFC-134a (R134a).

w/o No. 2 Air Conditioning Tube
780 to 880 g (27.5 to 31.0 oz.)
w/ No. 2 Air Conditioning Tube
700 to 800 g (24.7 to 28.2 oz.)

SST: 09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02140, 09985-02080 )

Note

Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.
Approximately 200 g (7.1 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the 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 A/C system.

WARM UP ENGINE
1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.
  
  Note
  
  Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
INSPECT FOR REFRIGERANT LEAK
1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
2. Carry out the test under the following conditions:
  - Turn the engine switch off.
  - Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
  - Repeat the test 2 or 3 times.
  - Make sure that there is some refrigerant remaining in the refrigeration system.
    
    When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
3. Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.
4. Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.
  Tech Tips
  
  After the blower motor has stopped, let the cooling unit stand 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 testing.
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 perform the test.
6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.
INITIALIZE SERVO MOTOR
1. Turn the engine switch off.
2. Connect the intelligent tester to the DLC3.
3. Turn the engine switch on (IG).
4. Press the A/C OFF switch.
5. Turn the intelligent tester on.
6. Enter the following menus: Body / Air Conditioner / Utility / Servomotor Initialization.
7. According to the intelligent tester display, select the "Next" switch.
8. According to the intelligent tester display, select the "Next" switch.
  
  Tech Tips
  
  During initialization, the AUTO indicator illuminates. When initialization is complete, the indicator turns off.
9. According to the intelligent tester display, select the exit to finish the initialization.