AIR CONDITIONING UNIT INSTALLATION

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.


  1. INSTALL BLOWER ASSEMBLY

    A01IPHJ

    1. Install the blower assembly with the 3 screws.

    2. Connect the connector.

    3. A01INPL

      w/ PTC Heater:

      Install the screw.

    4. A01IT3H

      w/ PTC Heater:

      Attach the 3 clamps.

  2. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A01IR2A

      Attach the 2 claws to install the No. 3 air duct sub-assembly.

  3. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A01IUQM

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

  4. TEMPORARILY INSTALL AIR CONDITIONING UNIT


    1. A01IUGW

      Temporarily install the air conditioning unit with the bolt and nut.

      Note


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

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

  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement assembly with the 8 bolts.

      A01INN7

    2. Connect each connector.

    3. Attach each clamp.

    4. Connect the wire harness and junction block and install each bolt.

      Torque:
      for bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      A01ITI6E08
      Text in Illustration
      *A except Manual Transaxle *B w/ PTC Heater
      *1 Specified Torque Bolt A - -

    5. Attach each clamp and connect the wire harness.

    6. Install the ground wire with the 2 bolts.

      A01IPVD

  6. INSTALL AIR CONDITIONING UNIT

    A01ISGT

    1. Tighten the bolt of the air conditioning unit.

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

    2. Tighten the nut of the air conditioning unit.

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

    3. Connect the drain cooler hose.

  7. INSTALL REAR NO. 2 AIR DUCT


    1. A01IP49

      Attach the 4 claws to install the rear No. 2 air duct.

  8. INSTALL INSTRUMENT PANEL BRACE ASSEMBLY

    A01IUCKE01
    Text in Illustration
    *A except Manual Transaxle
    *1 Screw

    1. Install the instrument panel brace assembly with the 3 bolts, 2 screws and 2 nuts.

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

    2. Attach each clamp.

    3. Connect the connector.

  9. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE


    1. A01IUAH

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

  10. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A01IR2J

      Attach the 6 claws to install the lower defroster nozzle assembly.

  11. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01IRTH

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

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

  12. INSTALL REAR NO. 1 AIR DUCT


    1. A01IRJL

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

    2. A01IR7E

      Install the floor carpet with the clip.

  13. INSTALL REAR NO. 3 AIR DUCT


    1. A01IS35

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

    2. A01INUN

      Install the floor carpet with the clip.

  14. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  15. INSTALL COWL SIDE TRIM BOARD LH

    A01ISRD

    1. Attach the 2 clips and guide to install the cowl side trim board.

  16. INSTALL FRONT DOOR SCUFF PLATE LH

    A01IPG9

    1. Attach the 8 claws and 2 clips to install the front door scuff plate.

  17. INSTALL COWL SIDE TRIM BOARD RH

    Tech Tips

    Use the same procedure described for the LH side.

  18. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  19. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  20. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  21. CONNECT HEATER OUTLET WATER HOSE AND HEATER INLET WATER HOSE


    1. A01ITUWE01
      Text in Illustration
      *1 Paint Mark (Width: 5 mm)
      *2 Paint Mark (Width: 2 mm)

      Connect the heater outlet water hose and heater inlet water hose with the paint mark facing up and attach the clip shown in the illustration.

  22. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the tube and air conditioning unit.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the air conditioner tube and accessory assembly.

  23. CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the pipe and air conditioning unit.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. A01IPS6

      Securely connect the suction pipe to the air conditioning unit.

    5. Move the hook connector in the direction indicated by the arrow in the illustration and install the bolt.

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

  24. INSTALL OUTER COWL TOP PANEL


    1. Install the outer cowl top panel with the 9 bolts.

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

  25. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)


    1. Install the 2 No. 1 vacuum transmitting hoses to the differential pressure sensor.

    2. Connect the 2 No. 1 vacuum transmitting hoses to the exhaust manifold converter sub-assembly.

    3. Using a T20 "TORX" socket wrench, install the differential pressure sensor with the screw.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Connect the differential pressure sensor connector and slide the white-colored lock to engage it securely.

  26. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A01ISAD

      Move the wiper motor and link in the direction shown by the arrow in the illustration to attach the wiper cushion to the body and install the wiper motor and link.

    2. A01ITHG

      Install the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    3. A01IQJZ

      Connect the connector and attach the clamp to install the wire harness to the cowl top panel.

  27. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. A01IPRQ

      Attach the 6 claws and 5 guides to install the cowl top ventilator louver LH.

    2. Install the clip.

    3. A01INVH

      Attach the 2 claws and 2 guides to install the center cowl top ventilator louver.

  28. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A01IQI1

      Attach the 4 claws and 5 guides to install the cowl top ventilator louver RH.

    2. Install the clip.

  29. INSTALL HOOD TO COWL TOP SEAL


    1. A01IQHZ

      Attach the 7 clips and 2 claws to install the hood to cowl top seal.

  30. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. Operate the wiper and stop the front wiper motor and link at the automatic stop position.

    2. A01ITA3E01
      Text in Illustration
      *1 Wiper Arm Serrations
      *2 Wire Brush
      *3 Wiper Pivot Serrations

      Clean the wiper arm serrations.

    3. When reusing the front wiper motor and link assembly:


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

    4. A01ITAIE01
      Text in Illustration
      *1 Mark for Blade Position

      Position the blade tip within the range shown in the illustration.

      Tech Tips

      The lower limit of the range is indicated by the mark on the glass.

    5. Install the front wiper arm and blade assembly LH with the nut.

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

      Tech Tips

      Hold the arm hinge by hand when tightening the nut.

    6. 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.

  31. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the front wiper motor and link at the automatic stop position.

    2. A01ITA3E01
      Text in Illustration
      *1 Wiper Arm Serrations
      *2 Wire Brush
      *3 Wiper Pivot Serrations

      Clean the wiper arm serrations.

    3. When reusing the front wiper motor and link assembly:


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

    4. A01ITNDE01
      Text in Illustration
      *1 Mark for Blade Position

      Position the blade tip within the range shown in the illustration.

      Tech Tips

      The lower limit of the range is indicated by the mark on the glass.

    5. Install the front wiper arm and blade assembly RH with the nut.

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

      Tech Tips

      Hold the arm hinge by hand when tightening the nut.

  32. INSTALL FRONT WIPER ARM HEAD CAP


    1. A01ISR6

      Install the front wiper arm head cap.

      Tech Tips

      Use the same procedure for all front wiper arm head caps.

  33. INSTALL NO. 2 CYLINDER HEAD COVER (for ZR Series Engine)


    1. A01IRS7

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.

  34. INSTALL NO. 1 ENGINE COVER (for 1WW)


    1. A01IQK8E02
      Text in Illustration
      *a Installation Points

      Attach the 4 clips to install the No. 1 engine cover.

      Tech Tips

      When attaching the clips, press the protrusions on the top of the No. 1 engine cover at the clip installation points.

  35. CHARGE REFRIGERANT

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

    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      440 +/-30 g (15.5 +/-1.1 oz)
      A01IS7RE26

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

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

  36. ADD ENGINE COOLANT (for 1ZR-FAE)


    1. Tighten the radiator drain cock plug.

    2. A01IRFF

      Add TOYOTA Super Long Life Coolant (SLLC) through the radiator reservoir filler opening until the coolant reaches the B line.

      Standard Capacity
      Item Specified Condition
      5-bladed fan 5.6 liters (5.9 US qts, 4.9 Imp. qts)
      7-bladed fan 6.3 liters (6.7 US qts, 5.5 Imp. 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.

    3. 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.

    4. Install the cap and warm up the engine sufficiently.

    5. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the air conditioning temperature setting to MAX (HOT).

      • Adjust the air conditioning blower setting to Lo.


      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. After the engine has warmed up, repeat the following procedure for at least 7 minutes: run the engine at 3000 rpm for 5 seconds, and then at idle speed for 45 seconds (repeat this procedure at least 8 times).

      3. 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.

    6. A01IRFF

      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.

  37. ADD ENGINE COOLANT (for 2ZR-FAE)


    1. Tighten the radiator drain cock plug.

    2. A01IRFF

      Add TOYOTA Super Long Life Coolant (SLLC) through the radiator reservoir filler opening until the coolant reaches the B line.

      Standard Capacity
      Item Specified Condition
      for Manual transaxle 5-bladed fan 5.6 liters (5.9 US qts, 4.9 Imp. qts)
      7-bladed fan 6.3 liters (6.7 US qts, 5.5 Imp. qts)
      for CVT 6.2 liters (6.6 US qts, 5.4 Imp. 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.

    3. 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.

    4. Install the cap and warm up the engine sufficiently.

    5. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the air conditioning temperature setting to MAX (HOT).

      • Adjust the air conditioning blower setting to Lo.


      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. After the engine has warmed up, repeat the following procedure for at least 7 minutes: run the engine at 3000 rpm for 5 seconds, and then at idle speed for 45 seconds (repeat this procedure at least 8 times).

      3. 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.

    6. A01IRFF

      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.

  38. ADD ENGINE COOLANT (for 1WW)

    CAUTION:

    Do not remove the reservoir cap and air release valve while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Tighten the radiator drain cock plug by hand.

    2. A01IND9E02
      Text in Illustration
      *1 Air Release Valve
      *a Radiator Reservoir Assembly Filler Neck
      *b Pour Limit Line

      Remove the air release valve.

    3. Add engine coolant to the pour limit line of the radiator reservoir assembly.

      Standard Capacity
      Item Specified Condition
      w/o Combustion Type Power Heater 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      w/ Combustion Type Power Heater 7.3 liters (7.7 US qts, 6.4 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips

      Toyota recommends the use of approved "Toyota Premium Long Life Coolant for 1WW/2WW engines" or equivalent.

    4. Press the No. 2 radiator hose and radiator hose sub-assembly several times by hand, and then check the level of the engine coolant.

      If the coolant level is low, add engine coolant.

    5. Install the air release valve.

    6. Add engine coolant to the filler neck of the radiator reservoir assembly.

    7. Install the reservoir cap.

    8. Start the engine, and warm it up until the cooling fan operates.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the air conditioning temperature setting to MAX (HOT).

      • Adjust the air conditioning blower setting to Lo.

    9. Maintain the engine speed at 2000 to 2500 rpm and warm up the engine until the cooling fan operates.

      Note


      • Make sure that the radiator reservoir assembly still has some engine coolant in it.

      • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough engine coolant, the engine may burn out or overheat.

      • Immediately after starting the engine, if the radiator reservoir assembly does not have any coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the coolant is filled to the pour limit line.

      • Until the coolant level has stabilized, run the engine at 2000 rpm.

    10. Press the No. 2 radiator hose and radiator hose sub-assembly several times by hand to bleed air.

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the cooling fan.

    11. Stop the engine and wait until the coolant cools down to ambient temperature.

    12. Check that the coolant level is between the FULL and LOW line.

      If the coolant level is below the LOW line, repeat all of the procedures above.

      If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.

  39. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    CAUTION:

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

  40. INSPECT FOR COOLANT LEAK (for 1ZR-FAE)

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    1. A01IPAH

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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator 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 leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

  41. INSPECT FOR COOLANT LEAK (for 2ZR-FAE)

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    1. A01IPAH

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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator 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 leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

  42. CHECK SRS WARNING LIGHT

    Click here

  43. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor by turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  44. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation observing the following instructions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A01IPCYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.