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Air Conditioning Unit: Installation

  1. INSTALL BLOWER ASSEMBLY 
    1. Install the blower with the 2 claws and screw.

      Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf) 

    2. Connect the connector.
  2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (See  INSTALLATION   ) 
    Fig 1: Identifying Screw, Claws And Connector
    G05306937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 AIR DUCT 
    1. Install the duct with the screw.
      Fig 2: Identifying No. 2 Air Duct With Screw
      G05297842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL UPPER FOOT DUCT 
    1. Attach the 2 claws and install the foot duct.
      Fig 3: Identifying Claws On Upper Foot Duct
      G05306936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL LOWER FOOT DUCT 
    1. Attach the 2 claws to install the foot duct.
      Fig 4: Identifying Claws On Lower Foot Duct
      G05306935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Install the A/C unit with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) 

  7. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Driver side:
      1. Using a T40 "TORX" socket, install the instrument panel reinforcement with the 3 "TORX" bolts.

        Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

        Fig 5: Identifying A/C Unit Assembly With Nut
        G05297841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 6: Removing Collars Using TORX Bolts (Driver Side)
        G05306978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Passenger side:
      1. Using a 12 mm hexagon wrench, install the instrument panel reinforcement with the 2 collars.

        Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      2. Using a T40 "TORX" socket, install the instrument panel reinforcement with the 5 "TORX" bolts.

        Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    3. Install the instrument panel reinforcement with the 6 bolts and 2 screws.

      Torque: 

      9.8 N*m (100 kgf*cm, 7 ft.*lbf) for bolt A 

    4. Install the bolt and cap.
      Fig 7: Identifying Bolt And Cap
      G05297885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 connectors and attach the 27 clamps.
    6. Install the 2 junction blocks with the 2 bolts and 3 nuts.
      Fig 8: Locating Clamps And Connectors
      G05306930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT TRANSPONDER KEY ECU 
    1. Install the transponder key ECU with the screw.
    2. Attach the clamp.
      Fig 9: Identifying Transponder Key ECU With Screw
      G05306929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL DEFROSTER LOWER NOZZLE ASSEMBLY 
    1. Attach the 4 claws and install the defroster lower nozzle.
      Fig 10: Identifying Claws
      G05306928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 1 CONSOLE BOX DUCT 
    1. Install the console box duct.
      Fig 11: Identifying No. 1 Console Box Duct
      G05297835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 CONSOLE BOX DUCT 
    1. Install the console box duct with the 2 clips.
  12. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY  (See INSTALLATION )
  13. INSTALL MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY  (see INSTALLATION )
  14. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
    Fig 12: Identifying No. 2 Console Box Duct With Clips
    G05297834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT PILLAR GARNISH RH  (See INSTALLATION )
  16. INSTALL GLOVE COMPARTMENT DOOR SUB-ASSEMBLY  (See INSTALLATION )
  17. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY  (See INSTALLATION )
  18. INSTALL STEERING CONTROL ECU  (See INSTALLATION )
  19. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  20. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY  (See INSTALLATION )
  21. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY  (See INSTALLATION )
  22. INSTALL NO. 1 INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY  (See INSTALLATION )
  23. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  24. INSTALL INSTRUMENT SIDE PANEL LH  (See INSTALLATION )
  25. INSTALL INSTRUMENT SIDE PANEL RH  (See INSTALLATION )
  26. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
  27. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  28. INSTALL CONSOLE BOX  (See INSTALLATION )
  29. INSTALL STEERING COLUMN ASSEMBLY 
  30. INSTALL CONSOLE BOX REGISTER ASSEMBLY  (See INSTALLATION )
  31. INSTALL CONSOLE BOX PLATE  (See INSTALLATION )
  32. INSTALL INSTRUMENT PANEL FINISH PANEL END LH  (See INSTALLATION )
  33. INSTALL INSTRUMENT PANEL FINISH PANEL END RH  (See INSTALLATION )
  34. INSTALL CONSOLE UPPER PANEL ASSEMBLY  (See INSTALLATION )
  35. INSTALL FRONT CONSOLE UPPER PANEL GARNISH  (See INSTALLATION )
  36. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY  (See INSPECTION )
  37. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY  (See INSTALLATION )
  38. INSTALL SPIRAL CABLE WITH STEERING SENSOR  (See INSTALLATION )
  39. INSTALL UPPER STEERING COLUMN COVER 
  40. INSTALL LOWER STEERING COLUMN COVER 
  41. INSTALL STEERING WHEEL ASSEMBLY 
  42. INSTALL STEERING PAD  (See INSTALLATION )
  43. INSTALL LOWER NO. 3 STEERING WHEEL COVER 
  44. INSTALL LOWER NO. 2 STEERING WHEEL COVER 
  45. INSTALL FRONT DOOR OPENING TRIM COVER LH  (See INSTALLATION )
  46. INSTALL FRONT DOOR OPENING TRIM COVER RH  (See INSTALLATION )
  47. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  48. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  49. INSTALL HEATER WATER INLET HOSE 
    1. Install the water hose and attach the clip.
  50. INSTALL HEATER WATER OUTLET HOSE 

    HINT:

    Use the same procedures described for the water inlet hose.

  51. CONNECT LIQUID TUBE SUB-ASSEMBLY 
    1. Remove the vinyl tape attached to the tube.
      Fig 13: Identifying Heater Water Hose
      G05297833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid tube.

      Compressor oil: 

      ND-OIL 11 or equivalent 

    3. Install the O-ring on the liquid tube.
    4. Connect the liquid tube to the fitting hole.
  52. CONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the vinyl tape attached to the pipe.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe.

      Compressor oil: 

      ND-OIL 11 or equivalent 

    3. Install the O-ring on the suction pipe.
    4. Move the hook connector in the direction indicated by the arrow in the illustration.
    5. Insert the pipe joints into the fitting holes securely and install the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) 

      Fig 14: Inserting Pipe Joints Into Fitting Holes Securely
      G05297892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  54. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  55. INSTALL FRONT FENDER TO COWL SIDE SEAL LH  (See INSTALLATION )
  56. INSTALL FRONT FENDER TO COWL SIDE SEAL RH  (See INSTALLATION )
  57. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  58. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  59. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  60. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY LH  (See INSTALLATION )
  61. INSTALL FRONT PILLAR TO FRONT SIDE SEAL SUB-ASSEMBLY RH  (See INSTALLATION )
  62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  63. ADD ENGINE COOLANT  (See REPLACEMENT )
  64. CHARGE REFRIGERANT (See  REPLACEMENT   ) 
  65. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  66. WARM UP ENGINE (See  REPLACEMENT   ) 
  67. CHECK FOR ENGINE COOLANT LEAKS  (See COOLING SYSTEM )
  68. CHECK FOR LEAKAGE OF REFRIGERANT (See  REPLACEMENT   ) 
  69. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION (2006/02-2006/07) ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  70. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (see DIAGNOSIS SYSTEM (2006/02-2006/07) ).
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