AIR CONDITIONING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Connect each connector.

    2. Engage each clamp to install the air conditioning harness assembly.

  2. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY


    1. Engage the 2 claws and install the air conditioning duct sub-assembly.

  3. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. Engage the 2 claws to install the No. 1 air duct sub-assembly.

  4. INSTALL BLOWER ASSEMBLY


    1. Engage the guide.

    2. Install the blower assembly with the 3 screws.

    3. Connect the connector.

    4. Engage each clamp.

    5. w/ PTC Heater:


      1. Connect the quick heater assembly connector with the screw.

  5. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY

    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. A0040RW

      Temporarily tighten the air conditioning unit assembly with the bolt and nut.

    2. Connect the drain cooler hose.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

  6. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement assembly with the 6 bolts <A>.

      A00409XE01

    2. Install the air conditioning unit assembly with the 3 bolts <B>

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    3. Engage each clamp.

  7. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. A0043U5

      Install the air conditioning unit assembly with the bolt and nut.

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

  8. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. Install the No. 3 air duct sub-assembly with the 2 nuts.

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

  9. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


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

    2. Engage the clamp.

  10. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. A00447I

      Install the defroster nozzle assembly as shown in the illustration.

    2. Engage the 3 claws.

  11. INSTALL NO. 3 SIDE DEFROSTER NOZZLE DUCT


    1. Install the No. 3 side defroster nozzle duct with the clip.

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


    1. Install the No. 2 instrument panel brace sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the bolt and nut.

    3. Engage each clamp.

    4. Connect each connector.

    5. Install the 3 screws.

    6. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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


    1. Install the No. 1 instrument panel brace sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the bolt and nut.

    3. Connect the center airbag sensor connectors to the center airbag sensor assembly as shown in the illustration.

      A0042FRE01
      Text in Illustration
      *1 Center Airbag Sensor Connector *2 Screw
      *3 Bolt *4 Earth Wire
      *5 Waterproof Sheet - -

      Note

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

    4. Check that the waterproof sheet on the top of the center airbag sensor is not folded or deformed.

    5. Check that there is no looseness in the installation parts of the center airbag sensor assembly.

    6. Connect each connector.

    7. Engage each clamp and claw.

    8. Install the screw.

    9. Install the 2 earth wires with the 2 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  14. INSTALL REAR NO. 1 AIR DUCT


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

  15. INSTALL REAR NO. 3 AIR DUCT


    1. Engage the 2 claws to install the rear No. 3 air duct.

    2. A004412

      Engage the fastener to install the floor carpet to the original position.

    3. Install the clip.

    4. A0042I6

      Install the floor carpet to the original position and engage the 2 claws to close the 2 door scuff plate clamps as shown in the illustration.

  16. INSTALL REAR NO. 2 AIR DUCT


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

    2. A00423F

      Engage the fastener to install the floor carpet to the original position.

    3. Install the clip.

    4. A0040VH

      Install the floor carpet to the original position and engage the 2 claws to close the 2 door scuff plate clamps as shown in the illustration.

  17. INSTALL REAR NO. 4 AIR DUCT


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

  18. INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. Engage the guide and claw to install the front floor caution plate cover.

  19. INSTALL FRONT SEAT ASSEMBLY LH

    for Manual Seat: Click here

    for Power Seat: Click here

  20. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  21. INSTALL STEERING POST ASSEMBLY

    Click here

  22. INSTALL HEADUP DISPLAY


    1. A003ZYG

      Install the headup display with the bolt and 2 nuts.

    2. Connect the connector.

    3. Engage the clamp.

  23. INSTALL ECU INTEGRATION BOX RH (for LHD)


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

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Engage the 3 clamps to connect the wire harness.

    3. Connect each connector.

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


    1. A00432C

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

      Note

      Be sure to engage each connector securely.

    2. A0041JB

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

    3. A0041FY

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

      Note

      Be sure to engage each connector securely.

    4. Engage the 2 clamps to connect the wire harness.

    5. Engage the 6 claws to install the junction block cover.

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

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    7. A00429JE01

      Engage the 2 claws to connect the 2 connectors (5) and (4) as shown in the illustration.

      Note

      Be sure to engage each connector securely.

    8. Connect the 3 connectors (3), (2) and (1) as shown in the illustration.

      Note

      Be sure to engage each connector securely.

    9. Engage the clamp to connect the wire harness.

  25. INSTALL ECU INTEGRATION BOX RH (for RHD)


    1. for LHD:


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

      2. Engage the 3 clamps to connect the wire harness.

      3. Connect each connector.

    2. for RHD:


      1. Install the ECU integration box RH with the nut and bolt.

        Torque:
        Nut
        5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
        Bolt
        13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      2. Engage the clamp to connect the wire harness.

      3. Connect each connector.

  26. INSTALL ECU INTEGRATION BOX LH (for RHD)


    1. Install the ECU integration box with the bolt and nut.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Engage the clamp to connect the wire harness.

    3. Connect each connector.

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


    1. A004105

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

    2. A0043Z5

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

    3. A0040VZ

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

    4. Engage the clamp to connect the wire harness.

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

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    6. Engage the 2 clamps to connect the wire harness.

    7. A00442EE01

      Engage the 2 claws to connect the 2 connectors (3) and (2) as shown in the illustration.

    8. Connect the connector (1).

  28. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  29. CONNECT OUTLET HEATER WATER HOSE


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

  30. CONNECT INLET HEATER WATER HOSE


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

  31. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioning 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 11 or equivalent

    3. Install the O-ring on the air conditioning tube and accessory assembly.

      Note


      • Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the air conditioning 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 11 or equivalent

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

      Note


      • Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the suction pipe sub-assembly.

    5. A00432Z

      Rotate 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 }

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


    1. A0043EB

      Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A0040ON

      Bend the water guard plate RH and engage the claw.

    3. A0040FH

      Bend the No. 1 heater air duct splash shield seal and engage the claw.

    4. A0040EX

      Engage the clamp to install the wire harness.

  34. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A00436K

      Install the cowl body mounting reinforcement LH with the 3 bolts.

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

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


    1. A0041EP

      Install the outer cowl top panel sub-assembly with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A00423N

      Bend the water guard plate RH and engage the claw.

    3. A0042ZP

      Bend the No. 1 heater air duct splash shield seal and engage the claw.

    4. A00422BE01

      Engage the clamp*2 of the wire harness.

    5. Engage the clamp*1 and connect the connector (w/ Windshield Deicer).

    6. Engage the clamp of the wire harness.

  36. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A0042J0

      Install the cowl body mounting reinforcement RH with the 3 bolts.

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

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  38. INSPECT FOR COOLANT LEAK (for Engine)

    CAUTION:

    Do not remove the reservoir tank cap 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. Remove the reservoir tank cap.

    2. A0043OJ

      Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

    3. Put the engine in inspection mode (maintenance mode) Click here.

    4. Warm up the engine.

    5. Using the reservoir cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm2, 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly and the heater hose around and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    6. Remove the radiator cap tester.

    7. Install the reservoir tank cap.

  39. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for Engine)


    1. A0043U0E02
      Text in Illustration
      *1 Full line
      *2 Low line

      Check that the engine coolant level is between the low and full lines when the engine is cold.

      Tech Tips

      If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the full line.

  40. 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)
      A0043LPE11
      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
      Standard charge amount
      440 to 500g (15.5 to 17.6oz.)
      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.

  41. WARM UP COMPRESSOR


    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).

  42. 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:


      • Power 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. A0043GFE40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Inspect for Leak

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

    4. A004341E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

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

      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.