AIR CONDITIONING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY


    1. B007UFC

      Install the air conditioning radiator assembly with the 3 screws.

    2. B007S32

      w/ PTC


      1. Install the wire harness with the screw.

  2. INSTALL AIR DUCT NO.2


    1. B007QVDE01

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

  3. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Install the air conditioner unit assembly with the 3 bolts.

      B007W8S

  4. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Driver seat:


      1. Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 Torx bolts.

    2. Passenger seat:


      1. Using a hexagon wrench 12 mm, install the instrument panel reinforcement assembly with the 2 bolts.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "Torx" bolts.

        B007VO2E02
        Text in Illustration
        *A for Manual Transmission - -
        *1 Collar *2 ''Torx'' Bolt
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Install the 2 bolts and nut. (AUTOMATIC TRANSMISSION)

    4. Install the 3 bolts and nut. (MANUAL TRANSMISSION)

    5. Install the 2 bolts and cap.

  5. INSTALL INSTRUMENT PANEL TO FLOOR BRACE SUB-ASSEMBLY

  6. CONNECT PARKING BRAKE CONTROL HANDLE SUB-ASSEMBLY

  7. INSTALL AIR DUCT NO.1

  8. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  9. INSTALL INSTRUMENT PANEL ASSEMBLY

    Click here

  10. INSTALL HEATER WATER HOSE INLET A

  11. INSTALL HEATER WATER HOSE OUTLET

  12. INSTALL COOLER REFRIGERANT LIQUID PIPE B


    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 cooler refrigerant liquid pipe B.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the cooler refrigerant liquid pipe B.

    4. Install the cooler refrigerant liquid pipe B.

  13. INSTALL COOLER REFRIGERANT SUCTION PIPE A


    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 cooler refrigerant suction pipe A.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the cooler refrigerant suction pipe A.

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

    5. B007UD1E01
      Text in Illustration
      *1 Cooler Refrigerant Suction Pipe A
      *2 Hook Connector
      *3 Cooler Refrigerant Liquid

      Insert the pipe joints into the fitting holes securely and tighten the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  14. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. Temporarily install the intercooler with the 3 bolts.

    2. Connect the No. 3 air hose and tighten the hose clamp as shown in the illustration.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note


      • Insert the hose until it is flush with the pipe spool end, install the clip and then check that it is securely connected.

      • Check that the hose does not interfere with any other parts.

      • Check that the hose is not twisted.

    3. Connect the No. 2 air hose and tighten the hose clamp as shown in the illustration.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note


      • Insert the hose until it is flush with the pipe spool end, install the clip and then check that it is securely connected.

      • Check that the hose does not interfere with any other parts.

      • Check that the hose is not twisted.

    4. Tighten the 3 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
      B007P0UE01

  15. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY (w/ Intercooler)


    1. Install the upper radiator support with the 6 bolts.

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

    2. Install the 2 screws.

    3. B007UCYE01

      Align the ends of the tape and the ends of the clamps (vehicle outer side), connect the hood lock control cable to the clamps and install the hood lock control cable with the 2 clamps.

  16. INSTALL HOOD LOCK ASSEMBLY (w/ Intercooler)


    1. Connect the hood lock control cable.

    2. Temporarily install the hood lock with the 3 bolts.

    3. Check the hood position and adjust the hood lock position Click here.

    4. Tighten the 3 bolts.

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

  17. INSTALL RADIATOR RESERVE TANK ASSEMBLY (w/ Intercooler)


    1. B007TCZE01

      Connect the No. 2 water by-pass hose as shown in the illustration.

    2. B007UX9E01

      Insert the radiator reserve tank into the 2 grommets and install the radiator reserve tank with the bolt.

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

    3. Connect the water by-pass hose as shown in the illustration.

  18. INSTALL WINDSHIELD WASHER JAR ASSEMBLY


    1. Connect the 2 connectors.

    2. Attach the clamp.

    3. Connect the washer hose.

    4. Insert the windshield washer jar into the body hole and install the windshield washer jar with the 2 bolts.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

    5. Attach the clamp.

    6. Connect the washer hose.

  19. ADD WINDSHIELD WASHER FLUID (w/ Intercooler)

  20. INSTALL NO. 1 AIR INLET DUCT (w/ Intercooler)


    1. Install the No. 1 air inlet duct with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the 2 clips.

  21. INSTALL NO. 2 AIR INLET DUCT


    1. Install the No. 2 air inlet duct with the 3 clips.

  22. INSTALL RADIATOR GRILLE (for Standard Body)


    1. Attach the 8 claws to install the radiator grille.

    2. Install the 4 clips and 2 screws.

  23. INSTALL RADIATOR GRILLE (for Wide Body)


    1. Attach the 10 claws to install the radiator grille.

    2. Install the 4 clips and 2 screws.

  24. INSTALL ENGINE UNDER COVER NO.1 (w/ Intercooler)

  25. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. B007S8R

      Engage the grommet as shown in the illustration.

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    3. Connect the connector.

  26. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. B007U8JE01

      Body type narrow:


      1. Install the cowl top ventilator louver sub-assembly with the 10 claws and 6 clips.

    2. Body type wide:


      1. Install the cowl top ventilator louver sub-assembly with the 11 claws and 7clips.

    3. Connect the washer hose.

  27. INSTALL COWL VENT COVER LH

  28. INSTALL COWL VENT COVER RH

  29. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. B007P9IE03

      Operate the wiper, and stop the windshield wiper motor assembly at the automatic stop position.

    2. Clean the wiper arm serrations.

    3. Clean the wiper pivot serrations with a wire brush (when reinstalling).

    4. B007OU5E01

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

      Torque:
      25 N*m  { 225 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

  30. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. B007P9IE03

      Clean the wiper arm serrations.

    2. Clean the wiper pivot serrations with a wire brush (when reinstalling).

    3. B007RZ9E01

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

      Torque:
      25 N*m  { 225 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

  31. INSTALL WINDSHIELD WIPER ARM COVER


    1. Install the 2 windshield wiper arm covers.

    2. Operate the front wipers while spraying water or washer fluid on the windshield. Make sure that the wipers function properly and there is no interference with the vehicle body.

  32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    Note

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

  33. ADD ENGINE COOLANT (for 2KD-FTV)


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)
      w/ Front Heater 14.2 liters (15.0 US qts, 12.5 Imp. qts)
      w/ Front and Rear Heaters 16.2 liters (17.1 US qts, 14.3 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only 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 (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the engine coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B007OES

      Add engine coolant up to the B line mark in the radiator reservoir assembly and install the radiator reservoir cap sub-assembly.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. B007W0B

      After the engine cools down, check that the engine coolant level is between the LOW and FULL level marks.

  34. ADD ENGINE COOLANT (for 2TR-FE)


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block water drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Rear Heater 11.2 liters (11.8 US qts, 9.9 Imp. qts)
      w/ Rear Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)

      Note

      Never use water as a substitute 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).

    4. Remove the 2-way that is located near the throttle body assembly.

    5. When air is bled and the engine coolant drains out, install the 2-way.

    6. Add coolant through the radiator reservoir assembly filler opening until the coolant reaches the B line and install the radiator reservoir cap sub-assembly. [*1]

    7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fans.

      Note


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

      • Do not start the engine when there is no engine coolant in the radiator reservoir assembly.

      • Make sure that the needle does not show an abnormally high temperature.

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

      Tech Tips


      • Press the No. 2 and No. 3 radiator hoses several times by hand, and then check the level of the engine coolant.

      • The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

    9. Check the engine coolant level in the radiator reservoir assembly. [*4]

      Tech Tips


      • If the engine coolant level is below the LOW line, repeat step *1 through *4.

      • If the engine coolant level is above the FULL line, drain engine coolant until the engine coolant level is between the FULL and LOW lines.

  35. ADD ENGINE COOLANT (for 5L-E)


    1. Fill the radiator reservoir assembly with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Front Heater 13.3 liters (14.1 US qts, 11.7 Imp. qts)
      w/ Front and Rear Heaters 15.3 liters (16.2 US qts, 13.5 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only 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 (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    2. B007OES

      Add coolant up to the B line mark in the radiator reservoir assembly and install the reservoir cap.

    3. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    4. B007W0B

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  36. ADD ENGINE COOLANT (for 1GD-FTV)


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with engine coolant to the top of the inlet.

      Standard capacity
      13.9 liters (14.6 US qts, 12.2 Imp qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    3. Loosen the bleeder plug of the water outlet sub-assembly.

    4. When air is bled and the engine coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B007OES

      Add engine coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap sub-assembly.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. B007W0B

      After the engine cools down, check that the engine coolant level is between the LOW and FULL line.

  37. CHARGE REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      B007T4RE01
      Standard
      Single A/C
      520 to 580g (18.3 to 20.5 oz.)
      Dual A/C
      670 to 730g (23.0 to 25.7 oz.)
      SST
      07110-58060   ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

      Tech Tips

      Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

  38. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      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.

  39. CHECK FOR ENGINE COOLANT LEAKS (for 2KD-FTV)

    CAUTION:

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


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  40. CHECK FOR ENGINE COOLANT LEAKS (for 2TR-FE)

    CAUTION:

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


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  41. CHECK FOR ENGINE COOLANT LEAKS (for 5L-E)

    CAUTION:

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


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.

  42. CHECK FOR ENGINE COOLANT LEAKS (for 1GD-FTV)

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine assembly and radiator assembly are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator assembly with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator assembly to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block sub-assembly and cylinder head sub-assembly.

  43. CHECK FOR LEAKAGE OF REFRIGERANT


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

    2. Carry out the test under the following conditions:


      • Stop the engine.

      • Secure good ventilation (the gas 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. B007S0PE02

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

    4. B007U25E01

      Bring the gas leak detector close to the drain hose with the detector's power off.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas 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 gas leak detector close to the pressure switch and perform the test.