AIR CONDITIONING UNIT INSTALLATION


  1. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT


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

      A003RL6

      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.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement assembly with the 6 bolts.

      Torque:
      <A>
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      A003UUVE01

    2. Connect each connector.

    3. Engage each clamp.

    4. Engage the wire harness and junction block with the 13 bolts.

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

    5. Engage the cooler drain hose.

      A003TJ8E01

    6. Engage each clamp and the wire harness.

  3. INSTALL AIR CONDITIONING UNIT


    1. A003S5ZE01

      Install the 3 bolts.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    2. A003TRL

      Install the bolt.

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

    3. Install the air conditioning unit with the nut.

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

  4. INSTALL HEATER COVER (except Cold Area)


    1. Engage the 4 claws and install the heater cover.

  5. INSTALL REAR NO. 2 AIR DUCT (for Cold Area)


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

  6. INSTALL INSTRUMENT PANEL BRACE ASSEMBLY


    1. A003SSEE01
      Text in Illustration
      *1 Screw

      Install the instrument panel brace assembly with the 2 bolts, 2 screws and 2 nuts.

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

    2. Engage each clamp.

  7. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE


    1. Install the center instrument panel to cowl brace with the 2 bolts.

  8. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


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

  9. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A003TWJ

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

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

  10. INSTALL REAR NO. 1 AIR DUCT (for Cold Area)


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

    2. Engage the clip and install the floor carpet.

  11. INSTALL REAR NO. 3 AIR DUCT (for Cold Area)


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

    2. Engage the clip and install the floor carpet.

  12. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Engage the 2 claws and 2 guides.

      Note

      Do not allow the wire harness to get caught in the claws.

    2. Install the screw <E> or <F>.

    3. Install the 2 bolts <G> or <H>.

    4. Install the 10 screws <I> or <J>.

      A003TOAE03

    5. Engage each clamp.

    6. Install the 2 screws <E> or <F>.

    7. Connect each connector and install the lower instrument panel sub-assembly.

      A003TQIE01

    8. When using a new lower instrument panel sub-assembly:


      1. A003UDO

        Immediately after installing the lower instrument panel sub-assembly, twist and cut off the portions shown in the illustration (joints for moulding).

    9. Engage the 3 claws to install the hood lock control cable assembly.

    10. Engage the 2 claws to install the DLC3.

  13. INSTALL ANTENNA CORD SUB-ASSEMBLY (for LHD)


    1. A003S4ME01

      Engage the 5 clamps and install the antenna cord sub-assembly.

    2. Connect the connector.

    3. Install the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    4. A003STUE01

      Engage the clamp.

    5. A003SDH

      Connect the connector.

  14. INSTALL ANTENNA CORD SUB-ASSEMBLY (for RHD)


    1. A003UT8E01

      Engage the 4 clamps and install the antenna cord sub-assembly.

    2. Connect the connector.

    3. Install the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    4. A003STUE01

      Engage the clamp.

    5. A003SDH

      Connect the connector.

  15. CONNECT TRANSMISSION INSTRUMENT PANEL SHIFT ASSEMBLY


    1. Install the transmission instrument panel shift assembly with the 4 nuts.

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

    2. Connect the connector and wire harness clamp to the transmission instrument panel shift assembly.

  16. INSTALL NO. 1 SWITCH HOLE BASE


    1. Connect the connectors.

    2. Engage the 2 claws and 2 clips, and install the No. 1 switch hole base.

  17. INSTALL LOWER NO. 2 INSTRUMENT PANEL FINISH PANEL


    1. A003UP7

      Engage the 2 clips and guide.

    2. Install the lower No. 2 instrument panel finish panel with the 2 screws <E> or <F>.

  18. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL


    1. A003TWU

      Engage the 2 clips and guide.

    2. Engage the 4 claws and 2 guides.

    3. Install the lower No. 1 instrument panel finish panel with the 2 screws <E> or <F>.

  19. INSTALL INSTRUMENT PANEL UNDER TRAY


    1. A003TDZ

      Engage the 4 claws and install the instrument panel under tray.

  20. INSTALL FRONT NO. 1 CONSOLE BOX INSERT


    1. Engage the guide.

    2. Engage the 3 claws and install the front No. 1 console box insert.

  21. INSTALL FRONT NO. 2 CONSOLE BOX INSERT


    1. Engage the guide.

    2. Engage the 3 claws and install the front No. 2 console box insert.

  22. INSTALL FUSE BOX OPENING COVER


    1. Connect each connector.

    2. Engage the 4 claws and 4 clips, to install the fuse box opening cover.

  23. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. Engage the guide.

    2. Engage the 3 claws and install the instrument panel No. 2 instrument panel under cover sub-assembly.

  24. INSTALL COWL SIDE TRIM BOARD LH


    1. Engage the guide and 2 clips, then install the cowl side trim board LH.

  25. INSTALL FRONT DOOR SCUFF PLATE LH


    1. Engage the 10 claws, then install the front door scuff plate LH.

  26. INSTALL COWL SIDE TRIM BOARD RH

    Tech Tips

    Use the same procedure as for the LH side.

  27. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

  28. INSTALL REAR CONSOLE BOX ASSEMBLY


    1. Engage the 4 claws.

    2. Install the rear console box assembly with the 4 bolts and 2 screws.

  29. INSTALL CONSOLE BOX CARPET


    1. Install the console box carpet.

  30. INSTALL AIR CONDITIONING CONTROL ASSEMBLY


    1. Connect the connector.

    2. Engage the 4 clips and install the air conditioning control assembly.

  31. INSTALL RADIO RECEIVER OPENING COVER WITH BRACKET (w/o Radio Receiver)


    1. Install the radio receiver opening cover with bracket with the 4 bolts <K>.

  32. INSTALL RADIO AND DISPLAY RECEIVER WITH BRACKET (for Radio and Display Type)


    1. Connect each connector.

    2. Install the radio and display receiver with bracket with the 4 bolts.

  33. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (except Radio Receiver Type)


    1. Engage the 4 clips and install the center instrument cluster finish panel sub-assembly.

  34. INSTALL RADIO RECEIVER WITH BRACKET (for Radio Receiver Type)


    1. Connect each connector.

    2. Engage the 4 clips.

    3. Install the radio receiver with bracket with the 4 bolts.

  35. INSTALL STEERING POST ASSEMBLY

    Click here

  36. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY


    1. Check that the power 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 driver side knee airbag connector.

      Note

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

    4. Engage the 6 claws and 2 guides.

    5. Temporarily install the driver side knee airbag assembly with the 2 bolts (upper side).

    6. Temporarily install the driver side knee airbag assembly with the 2 bolts (lower side).

    7. Install the driver side knee airbag assembly with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  37. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. A003S74E03

      Engage the guide.

    2. Engage the claw.

    3. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <C> or <D>.

  38. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. When using a new upper instrument panel sub-assembly:


      1. A003RQD

        Immediately before installing the upper instrument panel sub-assembly, twist and cut off the portions shown in the illustration (joints for moulding).

    2. When using a new upper instrument panel sub-assembly:


      1. A003TZOE02
        Text in Illustration
        *1 Protective Tape

        Apply protective tape to the areas shown in the illustration.

    3. Engage the 5 claws.

      Note


      • When installing the upper instrument panel sub-assembly, be careful not to damage it or the steering wheel assembly.

      • Do not allow the wire harness to get caught in the claws.

    4. Engage the 3 claws and the 4 clips.

    5. Install the 2 screws <C> or <D>.

    6. Install the 2 passenger airbag bolts <A> or <B>.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    7. Connect the connector and install the upper instrument panel sub-assembly.

      A003RTVE01

    8. Remove the protective tape.

  39. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY


    1. Check that the power 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 connector.

      Note

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

  40. INSTALL NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY


    1. w/ USB Audio System:


      1. Connect the connector and engage the clamp.

    2. A003S4FE02
      Text in Illustration
      *1 Protective Tape
      *2 Claw

      Apply protective tape to the area shown in the illustration.

    3. Insert the instrument panel box assembly in the direction indicated by arrow (1) in the illustration so that the taped portion does not come in contact with the lower No. 1 instrument panel finish panel.

    4. Push the instrument panel box assembly in the direction indicated by arrow (2) in the illustration so that the claw on the upper part of the instrument panel box assembly is inserted into the upper instrument panel sub-assembly.

    5. A003U6E

      Engage the 3 claws and 3 clips.

    6. Install the No. 1 instrument panel box door sub-assembly with the 2 screws <C> or <D>.

  41. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY


    1. A003UK1E03
      Text in Illustration
      *1 Hinge

      Insert the glove compartment door assembly horizontally and engage the 2 hinges.

      Note

      Engaging the hinges from the top will deform the hinges. Be sure to install the glove compartment door assembly horizontally.

    2. A003U44E02
      Text in Illustration
      *1 Stopper
      *2 Glove Compartment Door Stopper

      Bend portions (A) and (B) in the direction indicated by the arrows in the illustration to engage the 2 stoppers.

    3. Engage the claw, connect the glove compartment door stopper, and install the glove compartment door assembly.

  42. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL


    1. Engage the 4 claws and 6 clips.

    2. Install the lower center instrument panel finish panel with the 2 screws <E> or <F>.

  43. INSTALL UPPER CONSOLE PANEL


    1. Engage the 7 claws and install the upper console panel.

  44. INSTALL REAR CONSOLE BOX COVER


    1. Connect the connector.

    2. Engage the 2 guides and 4 clips to install the rear console box cover.

  45. INSTALL FRONT PILLAR GARNISH LH


    1. Remove the protective cover.

    2. A003UYPE01
      Text in Illustration
      *1 Protective Tape

      Make sure that the front pillar garnish clip is not damaged.

      Note


      • If there is any damage, replace the garnish clip with a new one.

      • When a garnish clip is being replaced, make sure to install it in the direction shown in the illustration.

    3. Engage the guide.

    4. Turn the end of the front pillar garnish clip 90° with needle-nosed pliers and install it to the front pillar garnish LH.

      Tech Tips

      Tape the tips of the needle-nosed pliers before use.

    5. A003TUX

      Engage the 2 clips to install the front pillar garnish LH.

  46. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH


    1. A003U8HE01
      Text in Illustration
      *1 Protective Tape
      *a Guide (A)
      *b Guide (B)

      Engage the 2 guides (B).

    2. Engage the 2 guides (A) and 5 claws, then install the front pillar garnish corner piece LH.

    3. Remove the protective tape.

  47. INSTALL FRONT PILLAR GARNISH RH

    Tech Tips

    Use the same procedure as for the LH side.

  48. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH

    Tech Tips

    Use the same procedure as for the LH side.

  49. INSTALL CENTER INSTRUMENT PANEL REGISTER ASSEMBLY


    1. Connect the connector.

    2. A003U5ME03

      Engage the 3 guides, 5 claws and 2 clips, and install the center instrument panel register assembly.

  50. INSTALL INSTRUMENT PANEL FINISH PANEL END LH


    1. A003SDS

      Engage the 4 clips and install the instrument panel finish panel end LH.

  51. INSTALL INSTRUMENT PANEL FINISH PANEL END RH


    1. A003ROO

      Engage the 4 clips and install the instrument panel finish panel end RH.

  52. INSTALL COMBINATION METER ASSEMBLY


    1. Connect the connector and temporarily install the combination meter assembly.

      Note

      When installing the combination meter assembly, do not damage the upper instrument panel sub-assembly or combination meter assembly.

    2. Install the combination meter assembly with the 4 screws.

  53. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY


    1. Engage the 2 claws and 4 clips, and install the instrument cluster finish panel assembly.

    2. Remove the applied protective tape on the steering column cover.

  54. INSTALL HEATER OUTLET WATER HOSE


    1. Install the water hose and attach the clip.

  55. INSTALL HEATER INLET WATER HOSE


    1. Use the same procedures described for the heater outlet water hose.

  56. INSTALL AIR CONDITIONING TUBE ASSEMBLY


    1. Remove the attached vinyl tape from the tube.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assembly.

      Compressor oil
      ND-OIL 11 or equivalent

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

    4. Install the air conditioner tube assembly.

  57. INSTALL SUCTION PIPE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor oil
      ND-OIL 11 or equivalent

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

    4. A003RJ0

      Move the hook connector in the direction indicated by the arrow in the illustration.

    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

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

  58. INSTALL OUTER COWL TOP PANEL


    1. A003SJJ

      Install the outer cowl top panel with the 8 bolts and nut.

      Torque:
      Bolt
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Engage the clamp.

    3. A003UBYE01
      Text in Illustration
      *1 No. 1 Heater Air Duct Splash Shield Seal
      *2 Water Guard Plate RH

      Bend the No. 1 heater air duct splash shield seal and water guard plate RH, and engage each claw.

  59. INSTALL COWL BODY MOUNTING REINFORCEMENT LH


    1. A003TIT

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

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  60. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A003TALE01

      Install the windshield wiper motor and link assembly with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Connect the connector.

  61. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. A003TAO

      Engage the clip and 6 claws, and install the cowl top ventilator louver LH.

  62. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A003U85

      Engage the clip and 11 claws, and install the cowl top ventilator louver RH.

  63. INSTALL HOOD TO COWL TOP SEAL


    1. Engage the 7 clips and install the hood to cowl top seal.

  64. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A003SZUE12
      Text in Illustration
      *1 Wiper Arm Serration
      *2 Wire Brush
      *3 Wiper Pivot Serration

      When reusing the front wiper arm and blade assembly RH:


      1. Clean the wiper arm serrations.

    3. When reusing the windshield wiper link assembly:


      1. Clean the wiper pivot serrations with a wire brush.

    4. A003U1SE02
      Text in Illustration
      *1 Louver Edge
      *2 Ceramic Notch

      Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

      Area Measurement
      A 17.5 to 32.5 mm (0.69 to 1.28 in.)

  65. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A003SZUE12
      Text in Illustration
      *1 Wiper Arm Serration
      *2 Wire Brush
      *3 Wiper Pivot Serration

      When reusing the front wiper arm and blade assembly LH:


      1. Clean the wiper arm serrations.

    3. When reusing the windshield wiper link assembly:


      1. Clean the wiper pivot serrations with a wire brush.

    4. A003TK0E02
      Text in Illustration
      *1 Louver Edge
      *2 Ceramic Notch

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

      Area Measurement
      A 25.5 to 40.5 mm (1.00 to 1.59 in.)

    5. Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

  66. INSTALL FRONT WIPER ARM HEAD CAP


    1. Install the 2 front wiper arm head caps.

  67. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. Connect the hose to the air release valve. (w/ Air Release Valve)

    3. Loosen the air release valve. (w/ Air Release Valve)

    4. Add TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank filler opening until coolant overflows from the air release valve. Then tighten the air release valve. (w/ Air Release Valve)

    5. Disconnect the hose from the air release valve. (w/ Air Release Valve)

    6. A003TGQE01
      Text in Illustration
      *1 B Line

      Add TOYOTA Super Long Life Coolant (SLLC) to the B line on 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.

    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. Put the engine in inspection mode Click here.

    9. Install the reservoir 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, 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.

    11. A003TGQE02
      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 lines.

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

  68. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  69. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      440 to 500 g (15.5 to 17.6 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 a gauge manifold set that had been used on 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.

  70. 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. A003T8A

      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 a radiator 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.

  71. 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.

  72. 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. A003T91E31
      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. A003U02E08
      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.

  73. INSPECT STEERING PAD


    1. Make sure that the horn sounds.

      Tech Tips

      If the horn does not sound, inspect the horn system Click here.

  74. INSPECT SRS WARNING LIGHT

    Click here

  75. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  76. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  77. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.