AIR CONDITIONING UNIT INSTALLATION


  1. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY

    Note


    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.

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


    1. A01JDA3

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

    2. Connect the drain cooler hose.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

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

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

      A01J9ZLE01

    3. Engage each clamp.

      A01JCEC

  3. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. A01JBC2

      Install the air conditioning unit with the nut 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 }

  4. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01JAW8

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

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

  5. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A01JBYC

      Engage the 6 claws and remove the lower defroster nozzle assembly.

    2. Engage the clamp.

  6. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. A01J9JI

      Install the defroster nozzle assembly as shown in the illustration.

    2. A01J8DO

      Engage the 3 claws.

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


    1. A01JA0Y

      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. Install the screw <B> and 2 nuts to the computer integration box RH.

    4. Engage each clamp.

    5. Connect each connector.

    6. Install the 3 screws <A>.

    7. Install the bolt and connect the earth wire.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      A01JBJXE01
      Text in Illustration
      *1 Screw <A> *2 Bolt
      *3 Earth wires *4 Screw <B>
      *5 Nut *6 Computer integration box RH

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


    1. A01JCUJ

      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. Check that the power switch is off.

    4. 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.

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

      Note

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

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

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

    8. Connect each connector.

    9. Engage each clamp and claw.

    10. Install the screw.

    11. Install the 2 bolts and connect the 2 earth wires.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      A01JAFQE01
      Text in Illustration
      *1 Center airbag sensor connector *2 Screw
      *3 Bolt *4 Earth wires
      *5 Waterproof Sheet - -

  9. INSTALL NO. 3 SIDE DEFROSTER NOZZLE DUCT


    1. A01JBDQ

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

  10. INSTALL REAR NO. 1 AIR DUCT


    1. A01JA8X

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

  11. INSTALL REAR NO. 3 AIR DUCT


    1. A01JBVE

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

    2. A01JBMVE01

      Engage the 2 claws and install the clip.

    3. Engage the fastener to install the floor carpet to the original position as shown in the illustration.

      Text in Illustration
      *1 Fastener
    4. A01JD75

      Engage each claw to close the door scuff plate clamps as shown in the illustration.

  12. INSTALL REAR NO. 2 AIR DUCT


    1. A01J8IY

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

    2. A01JD63E01

      Engage the 2 claws and install the clip.

    3. Engage the fastener to install the floor carpet to the original position as shown in the illustration.

      Text in Illustration
      *1 Fastener
    4. A01JCV6

      Engage each claw to close the door scuff plate clamps as shown in the illustration.

  13. INSTALL STEERING POST ASSEMBLY

    Click here

  14. INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY (for LHD)


    1. A01JBQP

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

      Note

      Be sure to engage each connector securely.

    2. A01JBIQ

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

    3. A01J9ET

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

      Note

      Be sure to engage each connector securely.

    4. A01JCHY

      Engage the 2 clamps to connect the wire harness.

    5. A01J9K0

      Engage the 6 claws to install the junction block cover.

    6. A01J910

      Install the driver side junction block assembly with the bolt and nut.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }
    7. A01J8KME01

      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.

  15. INSTALL FRONT PASSENGER SIDE JUNCTION BLOCK ASSEMBLY (for RHD)


    1. A01JA4C

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

    2. A01JBLS

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

    3. A01JCWL

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

    4. Engage the clamp to connect the wire harness.

    5. A01J9ME

      Install the front passenger side junction block assembly with the bolt and nut.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

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

    7. A01JCU5E01

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

    8. Connect the connector (1).

  16. INSTALL ECU INTEGRATION BOX LH (for RHD)


    1. A01JAW9

      Install the ECU integration box with the bolt and nut.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    2. Engage the clamp to connect the wire harness.

  17. INSTALL HEADUP DISPLAY


    1. A01JCF1

      Install the headup display with the bolt and 2 nuts.

    2. Connect the connector.

    3. Engage the clamp.

  18. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  19. CONNECT OUTLET HEATER WATER HOSE


    1. A01JCRZ

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

  20. CONNECT INLET HEATER WATER HOSE


    1. A01JCOU

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

  21. CONNECT 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 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.

  22. CONNECT SUCTION PIPE SUB-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 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. A01JAX4

      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 }

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


    1. A01J9P5

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

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01JBKT

      Bend the water guard plate RH and engage the claw.

    3. A01JC2W

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

    4. A01JCF9

      Engage the clamp to install the wire harness.

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


    1. A01J9HT

      Install the outer cowl top panel with the 9 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01J91Q

      Bend the water guard plate RH and engage the claw.

    3. A01JA93

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

    4. A01JB4QE01

      Engage the clamp*2 of the wire harness.

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

    6. A01JAH2

      Engage the clamp of the wire harness.

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


    1. A01JAL3

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

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

  26. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    1. A01JDA9

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

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

  27. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  28. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. Remove the reservoir tank cap.

    3. A01JC0TE01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the reservoir tank.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      7.2 liters (7.6 US qts, 6.3 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.8 US qts, 5.7 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).

      Note

      Never use water as a substitute for engine coolant.

    4. 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.

    5. Install the reservoir tank cap.

    6. Put the engine in inspection mode Click here.

    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 low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

        Tech Tips

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    8. A01JC0TE02
      Text in Illustration
      *1 Full Line
      *2 Low Line

      After the engine has cooled down, check that the coolant level is between full and low.

      If the coolant level is low, add coolant to the full line on the reservoir tank.

  29. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A01J9PZE05
      Standard
      470 g (16.6 oz.)
      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 on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the cooler compressor.

      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      • Avoid using the gauge manifold set that had been used for vehicles with conventional compressor oil (ND-OIL 8 or equivalent) as much as possible. This will cause compressor oil remaining in the manifold to enter the vehicle, resulting in insulation performance deterioration. A gauge manifold set that had been used 3 times or less can be reused if an appropriate one is not available.

      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.

  30. WARM UP COMPRESSOR


    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 on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  31. 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 power 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 (3.9 to 5.9 kgf/cm2, 57 to 85 psi)

    3. A01J8MGE31
      Text in Illustration
      *1 Inspect for Leak
      *2 Halogen Leak Detector

      Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

    4. A01J8DZE08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      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.

  32. 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. A01JB8R

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

    3. Put the engine in inspection 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 engine water pump assembly 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.