AIR CONDITIONING UNIT > INSTALLATION

for Preparation Click here

NOTICE:

1. Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause brackets of the air conditioning unit assembly to break.
   
2. When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent electrical components from being damaged.
   

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

2. Engage the cooler drain hose as shown in the illustration.
   

   NOTICE:

   Connect the cooler drain hose firmly to prevent water leaks.

1. Install the instrument panel reinforcement assembly with the 5 bolts <A>.
   

   Torque:

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

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

   Torque:

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

   HINT:

   Tighten the bolts in the order shown in the illustration.

   
   
   
   
   
   

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

   NOTICE:

   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. Engage each clamp.
   

7. Connect each connector.
   

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

   Torque:

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

   
   
   
   
   
   
   

   Text in Illustration 

   *1

   Center airbag sensor connector

   *2

   Earth wire

9. w/ PTC Heater:
   
   

   1. Connect the 2 connectors.
      

10. Install the brake pedal support assembly to the instrument panel reinforcement with the bolt.
    

    Torque:

    24 N*m{ 241 kgf*cm , 17 ft.*lbf }

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

2. Engage the clamp to connect the wire harness.
   

3. Connect each connector.
   

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

2. Install the bolt.
   

3. Engage the clamp.
   

4. Connect each connector.
   

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

2. Engage the clamp to connect the wire harness.
   

3. Connect each connector.
   

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

   NOTICE:

   Be sure to engage the connector securely.

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

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

   NOTICE:

   Be sure to engage the connector securely.

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

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

   Torque:

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

6. Connect each connector.
   

   NOTICE:

   Be sure to engage each connector securely.

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

   NOTICE:

   Be sure to engage the connector securely.

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

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

   NOTICE:

   Be sure to engage the connector securely.

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

   Torque:

   8.6 N*m{ 88 kgf*cm , 76 in.*lbf }

5. Connect each connector.
   

   NOTICE:

   Be sure to engage each connector securely.

1. Engage the guide.
   

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

   Torque:

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

1. Engage the 6 claws.
   

2. Install the lower defroster nozzle assembly with the 2 clips.
   

1. Install the No. 2 heater to register duct with the 3 clips.
   

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

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

1. Install the screw.
   

   Torque:

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

2. Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.
   

   Torque:

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

3. Engage each clamp.
   

4. Install the bolt and connect the earth wire.
   

   Torque:

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

1. Install the screw.
   

   Torque:

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

2. Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.
   

   Torque:

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

3. Engage each clamp.
   

4. Install the bolt and connect the earth wire.
   

   Torque:

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

1. Install the center instrument panel reinforcement sub-assembly with the bolt and nut.
   

   Torque:

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

1. Install the windshield wiper relay assembly with the bolt.
   

2. Connect the connector.
   

1. 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 }

1. Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft to connect the No. 2 steering intermediate shaft assembly to the steering intermediate shaft.
   

   Text in Illustration 

   *a

   Matchmark

2. Install the bolt.
   

   Torque:

   35 N*m{ 357 kgf*cm , 26 ft.*lbf }

1. Install the steering post assembly with the bolt and 2 nuts.
   

   Torque:

   Bolt:

   36 N*m{ 367 kgf*cm , 27 ft.*lbf }

   Nut:

   25 N*m{ 255 kgf*cm , 18 ft.*lbf }

2. Engage the wire harness clamps to the steering post assembly.
   

3. Engage the 2 wire harness clamps.
   

4. Connect the connector to the power steering ECU assembly.
   

5. Connect the connector to the power steering ECU assembly.
   

   Text in Illustration 

   *1	Lock Lever
   *2	Lock of Lock Lever

   HINT:

   As shown in the illustration, return the lock lever to its original position to connect the connector and securely push in the lock of the lock lever.

1. Install the steering post assembly with the bolt and 2 nuts.
   

   Torque:

   Bolt:

   36 N*m{ 367 kgf*cm , 27 ft.*lbf }

   Nut:

   25 N*m{ 255 kgf*cm , 18 ft.*lbf }

2. Engage the wire harness clamps to the steering post assembly.
   

3. Engage the 2 wire harness clamps.
   

1. Install the column hole cover silencer sheet with the 2 clips.
   

2. Install the floor carpet.
   

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

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

NOTICE:

1. Do not replace the spiral cable with the auxiliary battery connected and the power switch on (IG).
   
2. Do not rotate the spiral cable without the steering wheel with the auxiliary battery connected and the power switch on (IG).
   
3. Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor.
   
4. Do not remove the steering sensor from the spiral cable.
   

1. Using pliers, expand the clamp.
   

2. While holding the clamp expanded, install the turn signal switch assembly with spiral cable sub-assembly to the steering post assembly and engage the claw.
   

3. Return the clamp to its original position.
   

4. Connect the connectors to the turn signal switch assembly with spiral cable sub-assembly.
   

NOTICE:

If the steering column cover is installed in the incorrect order, it will not be possible to assemble the steering column cover.

1. Engage the 2 claws to install the steering column cover (upper side).
   

2. Engage the 4 clips and 2 guides to the steering column cover (upper side).
   

3. Engage the 4 claws to install the steering column cover (lower side).
   

4. Engage the 2 claws.
   

   HINT:

   Spread the claws and press the area around the claws to engage them.

5. Install the 2 screws.
   

   Torque:

   2.0 N*m{ 20 kgf*cm , 18 in.*lbf }

1. Install the nut to the brake pedal support assembly.
   

2. Install the brake pedal support assembly with the 4 nuts.
   

   Torque:

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

3. Engage the clamp.
   

4. Install the brake pedal support assembly to the instrument panel reinforcement with the bolt.
   

   Torque:

   24 N*m{ 241 kgf*cm , 17 ft.*lbf }

1. Apply lithium soap base glycol grease to the push rod pin and installation hole of the brake pedal support assembly.
   

2. Install the push rod pin and a new clip to connect the push rod clevis to the brake pedal support assembly.
   

1. Install the brake pedal return spring to the brake pedal support assembly and push rod pin.
   

1. Insert the stop light switch assembly until the rod hits the pedal.
   

   NOTICE:

   When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

2. Make a quarter turn clockwise to install the stop light switch assembly.
   

   Torque:

   1.5 N*m{ 15 kgf*cm , 13 in.*lbf } or less

   NOTICE:

   When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

3. Connect the connector.
   

4. Check the protrusion of the rod.
   

   Protrusion of the rod:

   1.5 to 2.5 mm (0.0591 to 0.0984 in.)
   

   If the protrusion is not as specified, adjust it.
   

   NOTICE:

   Do not depress the brake pedal.

1. Install the power steering ECU assembly with the bolt and 2 nuts.
   

   Torque:

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

2. Connect the 3 connectors to the power steering ECU assembly.
   

3. Connect the connector to the power steering ECU assembly.
   

   Text in Illustration 

   *1	Lock Lever
   *2	Lock of the Lock Lever

   HINT:

   As shown in the illustration, return the lock lever to its original position to connect the connector and securely push in the lock of the lock lever.

1. Install the power steering ECU assembly with the bolt and 2 nuts.
   

   Torque:

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

2. Connect the 3 connectors to the power steering ECU assembly.
   

3. Connect the connector to the power steering ECU assembly.
   

   Text in Illustration 

   *1	Lock Lever
   *2	Lock of the Lock Lever

   HINT:

   As shown in the illustration, return the lock lever to its original position to connect the connector and securely push in the lock of the lock lever.

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

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

1. Remove the attached vinyl tape from the pipe.
   

2. Apply a sufficiently amount of 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.
   

   NOTICE:

   1. Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter.
      
   2. 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.
   

1. Remove the attached vinyl tape from the pipe.
   

2. Apply a sufficient amount of 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.
   

   NOTICE:

   1. Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter.
      
   2. 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. 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 }

1. Install the reservoir tube assembly with the 2 bolts and nut.
   

   Torque:

   8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

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

   Torque:

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

2. w/ Wiper Deicer:
   Engage the 3 clamps to install the wire harness.
   

3. Engage the clamp to install the wire harness.
   

1. Install the cowl body mounting reinforcement RH with the 2 bolts.
   

   Torque:

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

1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.
   

1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.
   

HINT:

Use the same procedure for the RH side and LH side (Click here).

NOTICE:

Do not adjust the spiral cable with the auxiliary battery connected and the power switch on (IG).

1. Check that the power switch is off.
   

2. Check that the cable is disconnected from the negative (-) auxiliary battery terminal.
   

   CAUTION:

   Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

3. Rotate the spiral cable counterclockwise slowly by hand until it stops.
   

   NOTICE:

   Do not turn the spiral cable using the airbag wire harness.

4. Rotate the spiral cable clockwise approximately 2.5 turns to align the marks.
   

   Text in Illustration 

   *A	w/o Steering Heater
   *B	w/ Steering Heater
   *1	Alignment Mark

   NOTICE:

   Do not turn the spiral cable using the airbag wire harness.

   HINT:

   The spiral cable will rotate approximately 2.5 turns to both the left and right from the center.

1. Install the steering wheel assembly aligning the matchmarks on the steering wheel assembly and steering main shaft.
   

   Text in Illustration 

   *a

   Matchmark

2. Install the steering wheel assembly set nut.
   

   Torque:

   50 N*m{ 510 kgf*cm , 37 ft.*lbf }

3. Connect the connectors to the spiral cable and steering wheel assembly.
   

1. Tighten the radiator drain cock plug.
   

2. Add coolant to B line of the reserve tank.
   

   Text in Illustration 

   *1

   B Line

   Standard Capacity:

   Item	Capacity
   Engine coolant	w/ Exhaust Heat Recirculation System: 6.9 liters (7.3 US qts, 6.1 lmp. qts)
   	w/o Exhaust Heat Recirculation System: 6.5 liters (6.9 US qts, 5.7 lmp. qts)

   HINT:

   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).

   NOTICE:

   Never use water as a substitute for engine coolant.

3. Squeeze the radiator hoses several times by hand, and then check the level of the coolant.
   If the coolant level is low, add coolant.
   

4. Put the engine in inspection mode (Click here).
   

5. Install the reserve tank cap.
   

6. Bleed air from the cooling system.
   

   NOTICE:

   1. Before starting the engine, turn the A/C switch off.
      
   2. Adjust the heater control to the maximum hot setting.
      
   3. 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. (●1)
      

      HINT:

      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:

      1. Wear protective gloves.
         
      2. Be careful as the radiator hoses are hot.
         
      3. Keep your hands away from the radiator fans.
         

   2. Stop the engine and wait until the coolant cools down. Then if the coolant level is below the low line, add coolant so that the level will be between the full and low lines. (●2)
      

   3. Repeat the steps from (●1) to (●2) until the coolant level of the reserve tank remains above the low line.
      

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

   Text in Illustration 

   *1	Full Line
   *2	Low Line

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

1. Perform vacuum purging using a vacuum pump or appropriate equipment.
   

2. Charge the air conditioning system with refrigerant.
   

   Refrigerant type:

   HFC-134a (R134a)
   

   
   
   
   
   
   

   Standard charge amount:

   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)
   

   NOTICE:

   1. 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.
      
   2. The refrigerant amount should be checked by quantity (weight).
      
   3. The graph above is shown for reference only. This vehicle is not equipped with a sight glass.
      
   4. If at all possible, avoid using a manifold gauge set or recovery and recycling unit that has been used for vehicles with conventional compressor oil (ND-OIL 8 or equivalent). If either of these is used, conventional compressor oil remaining in the equipment will enter the air conditioning system of the vehicle, resulting in electrical insulation performance deterioration. A manifold gauge set that has been used 3 times or less can be used if an appropriate one is not available.
      

   HINT:

   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.

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.
   

   NOTICE:

   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).

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:
   

   1. Power switch off.
      
   2. Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).
      
   3. Repeat the inspection 2 or 3 times.
      
   4. 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. Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.
   

   Text in Illustration 

   *1	Halogen Leak Detector
   *a	Inspect for Leak

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

   Text in Illustration 

   *1	Halogen Leak Detector
   *2	Drain Hose

   HINT:

   1. After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
      
   2. Bring the halogen leak detector sensor under the drain hose.
      
   3. 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.
   

   HINT:

   When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

CAUTION:

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

NOTICE:

Before performing each inspection, turn the A/C switch off.

1. Remove the reserve tank cap.
   

2. Fill the reserve tank 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, the heater hose around the engine coolant temperature sensor 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 reserve tank cap.