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Front Air Conditioning Unit: Installation

  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Install the air conditioning unit with the 2 nuts.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 1: Identifying Air Conditioning Unit Nuts
      G05635513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AIR CONDITIONING HOSE AND ACCESSORY (w/ Cool Box) 
    1. Lubricate 2 new O-rings with compressor oil and install them to the air conditioning hose and accessory.

      Compressor oil: 

      ND-OIL 8 or equivalent 

      Fig 2: Identifying Proper Installation Position Of Air Conditioning Hose And Accessory
      G05284215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the air conditioning hose and accessory with the piping clamp.
      NOTE: After connection, check the claw engagement of the piping clamp.
    3. Install the bolt

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 3: Identifying Piping Clamp Bolt
      G05635510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Install the instrument panel reinforcement.
      1. Install the instrument panel reinforcement with the 7 bolts and screw.

        Torque: 

        for bolt 

        9.8 N*m (100 kgf*cm, 87 in.*lbf) 

        for screw 

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

      2. for Passenger Side:

        Using a 12 mm hexagon wrench, install the 2 collars.

        Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      3. for Passenger Side:

        Using a T40 "TORX" socket, install the 2 "TORX" bolts.

        Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      4. for Passenger Side:

        Install the 2 caps.

      5. for Driver Side:

        Install the 3 bolts.

        Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      6. for Driver Side:

        Install the 3 caps.

        Fig 4: Identifying Instrument Panel Reinforcement Assembly Bolts
        G05635577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamps to the wire harness and connect the connectors.
      Fig 5: Identifying Instrument Panel Reinforcement Caps And Bolts
      G05635508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL HEATER TO REGISTER DUCT ASSEMBLY 
    1. Attach the 2 claws to install the duct.
    2. Install the 3 clips.
      Fig 6: Identifying Heater To Register Duct Assembly Clips
      G05766695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL STEERING COLUMN ASSEMBLY 
    1. Install the steering column (See INSTALLATION ).
  6. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY 
    1. Attach the 2 claws to install the duct.
    2. Install the clip.
      3. Fig 7: Identifying Air Duct Claws
      G05635506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY 
    1. Install the instrument panel (See INSTALLATION ).
  8. INSTALL FRONT WIPER MOTOR AND BRACKET 
    1. Install the front wiper motor and bracket (See INSTALLATION ).
  9. CONNECT HEATER WATER INLET HOSE AND HEATER WATER OUTLET HOSE 
    1. Connect the 2 heater water hoses.
    2. Using pliers, grip the claws of the clips and slide the 2 clips.
      Fig 8: Locating Heater Water Hoses
      G05635505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT AIR CONDITIONING TUBE ASSEMBLY 
    1. Remove the attached vinyl tape from the tubes.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assembly.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    3. Install the 2 O-rings to the air conditioning tube assembly.
    4. Connect the air conditioning tube assembly.
    5. Attach the plate as shown in the illustration and install the bolt.

      Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 

      Fig 9: Connecting Air Conditioning Tube Assembly
      G05635582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  12. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (See CHECK MODE PROCEDURE ).
  13. ADD ENGINE COOLANT 
    1. Add engine coolant (See REPLACEMENT ).
  14. CHARGE REFRIGERANT  (See REPLACEMENT  )
  15. WARM UP ENGINE  (See REPLACEMENT  )
  16. CHECK FOR ENGINE COOLANT LEAK  (See COOLING SYSTEM )
  17. CHECK FOR REFRIGERANT GAS LEAK 
    1. Check for refrigerant gas leak (See REPLACEMENT  ).
  18. INSTALL UPPER RADIATOR SUPPORT SEAL  (See INSTALLATION )
  19. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  20. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  21. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  22. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH  (See INSTALLATION )
  23. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH  (See INSTALLATION )
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