AIR CONDITIONING UNIT > INSTALLATION

for Preparation Click here



1. INSTALL BLOWER ASSEMBLY


    E110815

  1. Engage the claw to install the blower assembly.



2. INSTALL WIRING AIR INDICATOR HARNESS NO.2 SUB-ASSEMBLY


    E110814

  1. Install the wiring air indicator harness No.2 sub-assembly with the 3 screws.

  1. Connect the connectors and clamp.



3. INSTALL AIR DUCT NO.2


    E110813

  1. Install the air duct No.2 with the screw.

    Torque:
    2.5 N*m{ 25 kgf*cm , 22 in.*lbf }



4. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY


    I035855

  1. Temporarily tighten the air conditioner unit assembly with the 2 nuts.

    HINT:
    Make sure to hold the air conditioner unit assembly securely as its bracket installation parts may be damaged.



5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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


    I036020

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



  1. Temporarily tighten the air conditioner unit assembly with the 2 nuts and bolt.


    I036030

  1. Install the 4 bolts and 4 nuts.

  1. Install the clamps.



  1. Connect the connectors.


    I035852



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


    I035851

  1. Install the instrument panel brace No.2 sub-assembly with the 3 bolts and 2 nuts.

  1. Install the clamps and connect the connectors.



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


    I035850

  1. Install the instrument panel brace No.1 sub-assembly with the 3 bolts and 2 nuts.

  1. Install the clamps and connect the connectors.



8. INSTALL INSTRUMENT PANEL BRACKET NO.4


9. INSTALL AIR DUCT NO.1 SUB-ASSEMBLY


    I035854E01

  1. Install the air duct No.1 sub-assembly with the 3 nuts.

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

    NOTICE:
    Tighten the bolts in numerical order shown in the illustration to install the air duct No.1 sub-assembly.



10. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY


  1. Fully tighten the air conditioner unit assembly with the 3 bolts and 4 nuts.


    I035870E02

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

    NOTICE:
    1. Tighten the bolts in numerical order shown in the illustration to install the air conditioner unit assembly.
    2. Install the air conditioner unit assembly so that there is no clearance between the duct and blower assemblies.



11. INSTALL STEERING COLUMN ASSEMBLY (Manual Tilt Type)


    C111434

  1. Install the steering column assembly with the 2 bolts and 2 nuts.

  1. Connect the connectors to the steering column assembly.



12. INSTALL STEERING COLUMN ASSEMBLY (Power Tilt and Power Type)


    C111450

  1. Install the steering column assembly with the 2 bolts and 2 nuts.

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

  1. Connect the connectors to the steering column assembly.

  1. Install the wire harness clamps to the steering column assembly.



13. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Manual Tilt Type)


    C111430E01

  1. Align matchmarks on the steering intermediate shaft sub-assembly and the power steering link assembly.



    C111478

  1. Install the bolt.

    Torque:
    35 N*m{ 360 kgf*cm , 26 ft.*lbf }



    C111429E01

  1. Tighten the bolt (B).

    Torque:
    35 N*m{ 360 kgf*cm , 26 ft.*lbf }

  1. Install the clamp to the steering column hole shield and tighten the bolt (A).



14. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Power Tilt and Power Type)


    C111430E01

  1. Align matchmarks on the steering intermediate shaft sub-assembly and the power steering link assembly.



    C111478

  1. Install the bolt.

    Torque:
    35 N*m{ 360 kgf*cm , 26 ft.*lbf }



    C111429E01

  1. Tighten the bolt (B).

    Torque:
    35 N*m{ 360 kgf*cm , 26 ft.*lbf }

  1. Install the clamp to the steering column hole shield and tighten the bolt (A).



15. INSTALL AIR DUCT NO.1


    E110812E01

  1. Install the air duct No.1 with the bolt.

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



16. INSTALL HYBRID VEHICLE CONTROL ECU

  1. Install the hybrid vehicle control ECU with the 2 nuts.

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

  1. Connect the 6 connectors to the hybrid vehicle control ECU.

  1. Connect the 3 wire harness clamps.



17. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY


    I036008

  1. Install the air conditioner amplifier assembly with the 2 nuts.



18. INSTALL SHIFT LEVER


    C116131E02

  1. Install the floor shift assembly with the 4 nuts.

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

    NOTICE:
    Tighten them in the order, A, B, C and D.



    C113140E01

  1. Install the pattern select switch connector, the shift lock control computer connector and the indicator light wire connector.



19. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

  1. Connect the socket of the transmission control cable assembly to the shift lever assembly.



    C116180

  1. Turn the socket of the transmission control cable assembly clockwise and install the stopper cap.

    NOTICE:
    Make sure that the transmission control cable assembly (socket) is firmly secured to the shift lever assembly.



    C116137E01

  1. Push the stopper cap to the socket as shown in the illustration.



    C116138E01

  1. Connect the control cable end to the shift lever assembly.

    NOTICE:
    1. Install the transmission control cable assembly with the graduated cuts to face upward to prevent torsion of the inner cable.
    2. Push the cable end to the bottom of the pin.
    3. Confirm that the connection between the socket and the shift lock control unit is fixed.



20. INSPECT SHIFT LEVER POSITION

  1. Apply the parking brake.

  1. Lock the wheels with chocks to secure the vehicle.

  1. Put the vehicle into the READY-on state.

  1. Move the shift lever to the D position and release the brake pedal.

    NOTICE:
    Be sure to apply the parking brake and lock the wheels with chocks to secure the vehicle.

  1. Slowly move the shift lever to the N position and measure moving distance (A) of the shift lever from the original point to the gear activation point.

    NOTICE:
    Be sure to move the shift lever slowly.

  1. Move the shift lever to the R position and release the brake pedal.

    NOTICE:
    Be sure to apply the parking brake and lock the wheels with chocks to secure the vehicle.

  1. Slowly move the shift lever to the N position and measure moving distance (B) of the shift lever from the original point to the vehicle activation point.

    NOTICE:
    Be sure to move the shift lever slowly.



  1. Check that moving distances (A) and (B) shown in the illustration are almost the same.


    C116133E01

    HINT:
    1. If moving distances (A) and (B) are almost the same, adjustment of the shift lever position is not necessary.
    2. If moving distance (A) is shorter than (B), perform adjustment of the shift lever position [*1].
    3. If moving distance (B) is shorter than (A), perform adjustment of the shift lever position [*2].



21. ADJUST SHIFT LEVER POSITION


  1. If moving distance (A) is shorter than (B) [*1]:


    C116134E01

    HINT:
    If the shift lever is moved from the R to N position, the moving distance of the shift lever from the original point to the gear activation point becomes longer.


    1. Move the shift lever to the N position.



      2. C108753

    2. Loosen the 2 bolts.



      3. C115287

    3. Slightly turn the park/neutral position switch counterclockwise.



      4. C108753E01

    4. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    5. Recheck the shift lever position.



  1. If moving distance (B) is shorter than (A) [*2]:


    C116135E01

    HINT:
    If the shift lever is moved from the D to N position, the moving distance of the shift lever from the original point to the gear activation point becomes longer.


    1. Move the shift lever to the N position.



      2. C108753

    2. Loosen the 2 bolts.



      3. C115288

    3. Slightly turn the park/neutral position switch clockwise.



      4. C108753E01

    4. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    5. Recheck the shift lever position.



22. INSTALL AIR DUCT REAR NO.1


23. INSTALL AIR DUCT REAR NO.2


24. INSTALL INSTRUMENT PANEL ASSEMBLY

HINT:
Refer to the installation procedures for the instrument panel assembly. (Click here)



25. INSTALL HEATER WATER INLET HOSE


26. INSTALL HEATER WATER OUTLET HOSE


27. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD Type:)


    I006878E02

  1. Remove the attached vinyl tape from the hose.

  1. Coat a new O-ring with compressor oil and install it to the hose.

    Compressor oil:
    ND-OIL 11 or equivalent

    NOTICE:
    1. Do not use any compressor oil other than ND-OIL 11 or equivalent.
    2. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

  1. Install the cooler refrigerant suction hose No.1 and piping clamp.

    HINT:
    1. Be sure to connect the hose securely.
    2. After connection, check the fitting for the claw of the piping clamp.



28. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1 (RHD Type:)


    I006878E02

  1. Remove the attached vinyl tape from the hose.

  1. Coat a new O-ring with compressor oil and install it to the hose.

    Compressor oil:
    ND-OIL 11 or equivalent

    NOTICE:
    1. Do not use any compressor oil other than ND-OIL 11 or equivalent.
    2. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

  1. Install the cooler refrigerant suction pipe No.1 and piping clamp.

    HINT:
    1. Be sure to connect the hose securely.
    2. After connection, check the fitting for the claw of the piping clamp.



29. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

  1. Remove the attached vinyl tape from the hose.

  1. Coat a new O-ring with compressor oil and install it to the pipe.

    Compressor oil:
    ND-OIL 11 or equivalent

    NOTICE:
    1. Do not use any compressor oil other than ND-OIL 11 or equivalent.
    2. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

  1. Install the air conditioning tube and accessory assembly and piping clamp.

    HINT:
    1. Be sure to connect the hose securely.
    2. After connection, check the fitting for the claw of the piping clamp.



30. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY

  1. Remove the 4 shock absorber nuts.



    A112528E01

  1. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

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

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).



31. INSTALL WINDSHIELD WIPER LINK ASSEMBLY


    E110471

  1. Install the windshield wiper motor and link assembly with the 5 bolts.

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

  1. Connect the connector.



32. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


33. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    B108016E03

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

  1. Clean the wiper arm serrations.

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



    E069045E01

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

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

    HINT:
    Hold the arm hinge by hand to fasten the nut.



34. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    B108016E03

  1. Clean the wiper arm serrations.

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



    E069046E01

  1. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

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

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.



35. ADD ENGINE COOLANT

  1. Tighten the lower drain plug of the radiator.

  1. Loosen the upper drain plug of the radiator.



    A080492E01

  1. Install a vinyl tube to the vent plug located on the upper drain plug.

  1. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

  1. Tighten the upper drain plug.

    CAUTION:
    1. Do not use an alcohol type coolant or plain water alone.
    2. The coolant must be mixed with plain water (preferably de-mineralized water).

      Capacity:
      9.7 liters (10.3 US qts, 8.5 lmp.qts)

    HINT:
    1. Improper coolants may damage engine cooling system.
    2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
    3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
    4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.

  1. Install the radiator cap securely.

  1. Fill the radiator reservoir tank with coolant.

  1. Warm up the engine.

    HINT:
    Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

  1. Stop the engine and wait until the coolant cools down.

  1. Remove the radiator cap and check the coolant level inside the radiator.

  1. If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

  1. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.



36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


37. CHARGE WITH REFRIGERANT

  1. Perform vacuum purging using a vacuum pump.



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


    I030082E03

    Standard:
    550 to 650 g (19.4 to 22.9 oz.)

    SST
    07110-58060   (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

    NOTICE:
    1. Do not turn the A/C on before charging with refrigerant because the compressor will overheat as a result of the cooler compressor not working properly without refrigerant.
    2. Approximately 100 g (3.53 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.
    3. Avoid using the gauge manifold set that had been used for vehicles with conventional compressor oil (ND-OIL8 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.

    HINT:
    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 COMPRESSOR

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

    NOTICE:
    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.



39. CHECK FOR ENGINE COOLANT LEAKS


A078989

CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

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

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.



40. CHECK FOR LEAKAGE OF REFRIGERANT

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

  1. Carry out the test under the following conditions:

    1. IG OFF
    2. Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
    3. Repeat the test 2 or 3 times.
    4. 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)



    I042222E02

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



    N014519E01

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

    HINT:
    1. After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
    2. Bring the gas leak detector sensor under the drain hose.
    3. 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.

  1. 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.

  1. 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.



41. REMOVE PERFORM INITIALIZATION

NOTICE:
Some systems need initialization when disconnecting the cable from the negative battery terminal. (Click here)