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Air Conditioning Unit: Installation

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Provisionally install the air conditioning unit assembly.
    2. Insert the bracket hook into the holes of the reinforcement bracket, and provisionally install the reinforcement.
    3. Install the instrument panel reinforcement with the 7 bolts.
    4. Install the 2 caps.
      Fig 1: Installing Instrument Panel Reinforcement With Bolts
      G04411458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 5 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      NOTE: Tighten the bolts in the sequence order shown in Fig 2 to install the air conditioner unit assembly.
    6. Install the 2 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 2: Installing Nuts & Bolts
      G04411459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Engage the 20 clamps.
      Fig 3: Engaging Clamps
      G04411460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the connector.
    9. Connect the 2 airbag connectors.
    10. Install the 3 bolts.
      Fig 4: Connecting Airbag Connectors And Bolts
      G04411461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Engage the 2 clamps and connect the 6 connectors to the air conditioning unit assembly.
      Fig 5: Engaging Clamps & Connecting Connectors To Air Conditioning Unit Assembly
      G04411462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY 
    1. Install the air conditioner amplifier assembly with the nut.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

    2. Connect the connector.
      Fig 6: Installing Air Conditioner Amplifier Assembly With Nut
      G04411463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSPONDER KEY ECU ASSEMBLY 
    1. Install the transponder key ECU assembly with the nut.
    2. Connect the connector.
      Fig 7: Installing Transponder Key ECU Assembly With Nut
      G04411464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL DRIVER SIDE JUNCTION BLOCK 
    1. Install the driver side junction block assembly with the 2 nuts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Install the bracket with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  5. INSTALL ECM (for 2TR-FE) (See  INSTALLATION  ) 
  6. INSTALL ECM (for 1GR-FE) (See  INSTALLATION  ) 
    Fig 8: Installing Driver Side Junction Block Assembly With Nuts & Bolts
    G04411465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL PARKING BRAKE CONTROL LEVER ASSEMBLY (for Lever Type Parking Brake) (See  INSTALLATION  ) 
  8. INSTALL STEERING COLUMN ASSEMBLY (See  INSTALLATION  ) 
  9. INSTALL STEERING SLIDING YOKE (See  INSTALLATION  ) 
  10. INSTALL STEERING COLUMN HOLE COVER (See  INSTALLATION  ) 
  11. INSTALL NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET 
    1. Install the instrument panel brace mounting bracket RH with the bolt and nut.
      Fig 9: Installing Instrument Panel Brace Mounting Bracket RH With Bolt & Nut
      G04411466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the instrument panel brace mounting bracket LH with the bolt and nut.
      Fig 10: Installing Instrument Panel Brace Mounting Bracket LH With Bolt & Nut
      G04411467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL AIR DUCT ASSEMBLY RH 
    1. Engage the 3 claws and install the air duct assembly.
      Fig 11: Installing Air Duct Assembly & Engaging Claws
      G04411468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL AIR DUCT ASSEMBLY LH 
    1. Engage the 4 claws and install the air duct assembly heater.
    2. Engage the clip.
      Fig 12: Installing Air Duct Assembly Heater & Engaging Claws
      G04411469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 REAR AIR DUCT (for Double Cab) 
    1. Engage the 2 claws and install the air duct rear.
    2. Put the floor carpet back down.
      Fig 13: Installing No. 1 Rear Air Duct & Engaging Claws
      G04411470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL NO. 2 REAR AIR DUCT (for Double Cab) 
    1. Engage the 2 claws and install the air duct rear.
    2. Put the floor carpet back down.
      Fig 14: Installing No. 2 Rear Air Duct & Engaging Claws
      G04411471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL NO. 3 HEATER TO REGISTER DUCT 
    1. Install the heater to register duct with the nut.
      Fig 15: Installing Heater To Register Duct With Nut
      G04411472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 1 HEATER REGISTER DUCT 
    1. Install the heater to register duct with the nut.
  18. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY W/ PASSENGER AIRBAG ASSEMBLY (See  INSTALLATION  ) 
  19. CONNECT PASSENGER AIRBAG CONNECTOR 
  20. INSTALL INSTRUMENT SIDE PANEL RH (See  INSTALLATION  ) 
  21. INSTALL INSTRUMENT LOWER COVER SUB-ASSEMBLY (See  INSTALLATION  ) 
    Fig 16: Installing Heater To Register Duct With Nut
    G04411473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL LOWER INSTRUMENT PANEL LH (See  INSTALLATION  ) 
  23. INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH (See  INSTALLATION  ) 
  24. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See  INSTALLATION  ) 
  25. INSTALL INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY (See  INSTALLATION  ) 
  26. INSTALL COMBINATION METER ASSEMBLY (See  INSTALLATION  ) 
  27. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See  INSTALLATION  ) 
  28. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL (See  INSTALLATION  ) 
  29. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY (See  REASSEMBLY  ) 
  30. INSTALL RADIO RECEIVER ASSEMBLY (See  INSTALLATION  ) 
  31. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (See  INSTALLATION  ) 
  32. INSTALL FRONT CONSOLE BOX (for Manual Transmission on Bench Seat Type) (See  INSTALLATION  ) 
  33. INSTALL FRONT CONSOLE BOX (for Automatic Transmission on Bench Seat Type) (See  INSTALLATION  ) 
  34. INSTALL FRONT CONSOLE BOX (for Manual Transmission on Separate Seat Type) (See  INSTALLATION  ) 
  35. INSTALL FRONT CONSOLE BOX (for Automatic Transmission on Separate Seat Type) (See  INSTALLATION  ) 
  36. INSTALL INSTRUMENT PANEL CUP HOLDER TRAY (for Automatic Transmission on Separate Seat Type) (See  INSTALLATION  ) 
  37. INSTALL REAR CONSOLE BOX ASSEMBLY (for Separate Seat Type) (See  INSTALLATION  ) 
  38. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Manual Transmission on Separate Seat Type) (See  INSTALLATION  ) 
  39. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Automatic Transmission on Separate Seat Type) (See  INSTALLATION  ) 
  40. INSTALL INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake) (See  INSTALLATION  ) 
  41. INSTALL INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake) (See  INSTALLATION  ) 
  42. INSTALL FRONT PILLAR GARNISH LH (for Regular Cab) (See  INSTALLATION  ) 
  43. INSTALL FRONT PILLAR GARNISH LH (for Access Cab) (See  INSTALLATION  ) 
  44. INSTALL FRONT PILLAR GARNISH LH (for Double Cab) (See  INSTALLATION  ) 
  45. INSTALL FRONT PILLAR GARNISH RH (for Regular Cab) (See  INSTALLATION  ) 
  46. INSTALL FRONT PILLAR GARNISH RH (for Access Cab) (See  INSTALLATION  ) 
  47. INSTALL FRONT PILLAR GARNISH RH (for Double Cab) (See  INSTALLATION  ) 
  48. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
  49. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
  50. INSTALL COWL SIDE TRIM BOARD LH (for Regular Cab) (See  INSTALLATION  ) 
  51. INSTALL COWL SIDE TRIM BOARD LH (for Access Cab) (See  INSTALLATION  ) 
  52. INSTALL COWL SIDE TRIM BOARD LH (for Double Cab) (See  INSTALLATION  ) 
  53. INSTALL COWL SIDE TRIM BOARD RH (for Regular Cab) (See  INSTALLATION  ) 
  54. INSTALL COWL SIDE TRIM BOARD RH (for Access Cab) (See  INSTALLATION  ) 
  55. INSTALL COWL SIDE TRIM BOARD RH (for Double Cab) (See  INSTALLATION  ) 
  56. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) (See  INSTALLATION  ) 
  57. INSTALL FRONT DOOR SCUFF PLATE LH (for Access Cab) (See  INSTALLATION  ) 
  58. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) (See  INSTALLATION  ) 
  59. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (See  INSTALLATION  ) 
  60. INSTALL FRONT DOOR SCUFF PLATE RH (for Access Cab) (See  INSTALLATION  ) 
  61. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab) (See  INSTALLATION  ) 
  62. INSTALL FRONT FLOOR FOOTREST (See  FRONT FLOOR FOOTREST  ) 
  63. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (See  INSTALLATION  ) 
  64. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See  INSTALLATION  ) 
  65. CENTER SPIRAL CABLE (See  INSTALLATION  ) 
  66. INSTALL STEERING COLUMN COVER UPPER (See  INSTALLATION  ) 
  67. INSTALL STEERING COLUMN COVER LOWER (See  INSTALLATION  ) 
  68. INSTALL STEERING WHEEL ASSEMBLY (See  INSTALLATION  ) 
  69. INSTALL HORN BUTTON ASSEMBLY (See  INSTALLATION  ) 
  70. INSTALL NO. 3 STEERING WHEEL COVER LOWER (See  INSTALLATION  ) 
  71. INSTALL NO. 2 STEERING WHEEL COVER LOWER (See  INSTALLATION  ) 
  72. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See  INSTALLATION  ) 
  73. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See  INSTALLATION  ) 
  74. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See  INSTALLATION  ) 
  75. INSTALL FRONT WIPER ARM RH (See  INSTALLATION  ) 
  76. INSTALL FRONT WIPER ARM LH (See  INSTALLATION  ) 
  77. INSTALL FRONT WIPER ARM HEAD CAP (See  INSTALLATION  ) 
  78. INSTALL HEATER WATER OUTLET HOSE (for 2TR-FE) 
    1. Install the heater water outlet hose onto the heater unit.
      NOTE: Make sure that the hose clip and mark are at the correct angle when installing. View A
      Fig 17: Installing Heater Water Outlet Hose Onto Heater Unit (2TR-FE)
      G04411474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL HEATER WATER OUTLET HOSE (for 1GR-FE) 
    1. Install the heater water outlet hose onto the heater unit.
      NOTE: Make sure that the hose clip and mark are at the correct angle when installing.
      Fig 18: Installing Heater Water Outlet Hose Onto Heater Unit (1GR-FE)
      G04411475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL HEATER WATER INLET HOSE (for 2TR-FE) 
    1. Install the heater water inlet hose onto the heater unit.
      NOTE: Make sure that the hose clip and mark are at the correct angle when installing.
      Fig 19: Installing Heater Water Inlet Hose Onto Heater Unit (2TR-FE)
      G04411476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL HEATER WATER INLET HOSE (for 1GR-FE) 
    1. Install the heater water inlet hose onto the heater unit.
      NOTE: Make sure that the hose clip and mark are at the correct angle when installing.
      Fig 20: Installing Heater Water Inlet Hose Onto Heater Unit (1GR-FE)
      G04411477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. INSTALL AIR CONDITIONING TUBE ASSEMBLY 
    1. Apply compressor oil to 2 new O-rings and install them onto the hose.

      Compressor oil: RL-897 or equivalent 

    2. Install the air conditioner tube and piping clamp.

      HINT:

      Check that the claw of the piping clamp is correctly fitted.

      Fig 21: Installing Air Conditioning Tube & Piping Clamp
      G04411478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bracket with the bolt and 2 clamps.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 22: Installing Bracket With Bolt & Clamps
      G04411479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Apply compressor oil to 2 new O-rings and install them onto the pipe.

      Compressor oil: RL-897 or equivalent 

    2. Install the suction hose and piping clamp.

      HINT:

      Check that the claws of the piping clamp are correctly fitted.

      Fig 23: Installing Suction Hose & Piping Clamp
      G04411480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bracket with the 2 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  84. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 

  85. ADD ENGINE COOLANT (for 2TR-FE) (See  COOLANT  ) 
  86. ADD ENGINE COOLANT (for 1GR-FE) (See  COOLANT  ) 
  87. CHECK FOR ENGINE COOLANT LEAKAGE (for 2TR-FE) (See  COOLANT  ) 
  88. CHECK FOR ENGINE COOLANT LEAKAGE (for 1GR-FE) (See  COOLANT  ) 
  89. CHARGE REFRIGERANT (See  REPLACEMENT   ) 
  90. WARM UP ENGINE (See  REPLACEMENT   ) 
  91. CHECK FOR REFRIGERANT LEAKAGE (See  REPLACEMENT   ) 
  92. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  93. INSPECT SRS WARNING LIGHT (See  TERMINALS OF ECU  ) 
    Fig 24: Installing Bracket With Bolts
    G04411481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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