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Air Conditioning Unit: Installation

  1. INSTALL BLOWER ASSEMBLY 
    1. Engage the claw to install the blower assembly.
    Fig 1: Engaging Claw To Installing Blower Assembly
    G05277604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL WIRING AIR INDICATOR HARNESS NO.2 SUB-ASSEMBLY 
    1. Install the wiring air indicator harness No.2 sub-assembly with the 3 screws.
    2. Connect the connectors and clamp.
    Fig 2: Identifying Wiring Air Indicator Harness No.2 Connector With Screw And Clamp
    G05273353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL AIR DUCT NO.2 
    1. Install the air duct No.2 with the screw.

    Torque: 2.5 N*m (25 kgf*cm, 22 in.*lbf) 

    Fig 3: Identifying Air Duct No.2 Screw With Claws
    G05273352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY 
    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.

    Fig 4: Identifying Air Conditioner Unit Assembly Nuts
    G05273351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Install the instrument panel reinforcement with the 8 bolts.
      Fig 5: Identifying Instrument Panel Reinforcement Bolts
      G05273389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Temporarily tighten the air conditioner unit assembly with the 2 nuts and bolt.
      Fig 6: Identifying Air Conditioner Unit Assembly With Nuts And Bolt
      G05273390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 bolts and 4 nuts.
    4. Install the clamps.
    5. Connect the connectors.
    Fig 7: Identifying Instrument Panel Reinforcement Assembly With Bolts And Nuts
    G05273349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INSTRUMENT PANEL BRACE NO.2 SUB-ASSEMBLY 
    1. Install the instrument panel brace No.2 sub-assembly with the 3 bolts and 2 nuts.
    2. Install the clamps and connect the connectors.
    Fig 8: Identifying Instrument Panel Brace No.2 Sub-Assembly With Bolts And Nuts
    G05273347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL INSTRUMENT PANEL BRACE NO.1 SUB-ASSEMBLY 
    1. Install the instrument panel brace No.1 sub-assembly with the 3 bolts and 2 nuts.
    2. Install the clamps and connect the connectors.
      3. Fig 9: Identifying Instrument Panel Brace No.1 Sub-Assembly With Bolts, Nuts And Clamp
      G05862336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL INSTRUMENT PANEL BRACKET NO.4 
  9. INSTALL AIR DUCT NO.1 SUB-ASSEMBLY 
    1. Install the air duct No.1 sub-assembly with the 3 nuts.

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

    NOTE: Tighten the bolts in numerical order shown in the illustration to install the air duct No.1 sub-assembly.
    Fig 10: Identifying Tightening Sequence Of Air Duct No.1 Sub-Assembly Nuts
    G05273394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY 
    1. Fully tighten the air conditioner unit assembly with the 3 bolts and 4 nuts.
    Fig 11: Identifying Tightening Sequence Of Air Conditioner Unit Assembly Bolts
    G05273395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    NOTE:
    • Tighten the bolts in numerical order shown in the illustration to install the air conditioner unit assembly.
    • 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)  (See INSTALLATION )
  12. INSTALL STEERING COLUMN ASSEMBLY (Power Tilt and Power Type)  (See INSTALLATION )
  13. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Manual Tilt Type)  (See INSTALLATION )
  14. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Power Tilt and Power Type)  (See INSTALLATION )
  15. INSTALL AIR DUCT NO.1 
    1. Install the air duct No.1 with the bolt.

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

    Fig 12: Locating Air Duct No.1 Bolt
    G05273396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL HYBRID VEHICLE CONTROL ECU  (See INSTALLATION )
  17. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY  (See INSTALLATION )
  18. INSTALL SHIFT LEVER  (See INSTALLATION )
  19. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See INSTALLATION )
  20. INSPECT SHIFT LEVER POSITION  (See ADJUSTMENT )
  21. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT )
  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. (See INSTALLATION )

  25. INSTALL HEATER WATER INLET HOSE 
  26. INSTALL HEATER WATER OUTLET HOSE 
  27. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1 
    1. Remove the attached vinyl tape from the hose.
    2. Coat a new O-ring with compressor oil and install it to the hose.
      Fig 13: Installing Cooler Refrigerant Suction Pipe No.1
      G05236269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Compressor oil: 

      ND-OIL 11 or equivalent 

      NOTE:
      • 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 leakage of electric power.
    3. Install the cooler refrigerant suction pipe No.1 and piping clamp.

    HINT:

    • Be sure to connect the hose securely.
    • After connection, check the fitting for the claw of the piping clamp.
  28. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the attached vinyl tape from the hose.
    2. Coat a new O-ring with compressor oil and install it to the pipe.

      Compressor oil: 

      ND-OIL 11 or equivalent 

      NOTE:
      • 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 leakage of electric power.
    3. Install the air conditioning tube and accessory assembly and piping clamp.

    HINT:

    • Be sure to connect the hose securely.
    • After connection, check the fitting for the claw of the piping clamp.
  29. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY  (See INSTALLATION )
  30. INSTALL WINDSHIELD WIPER LINK ASSEMBLY  (See INSTALLATION )
  31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
  32. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  33. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  34. ADD COOLANT (for Engine)  (See COOLANT (FOR ENGINE) )
  35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  36. CHARGE WITH REFRIGERANT  (See REPLACEMENT )
  37. WARM UP COMPRESSOR  (See REPLACEMENT )
  38. INSPECT FOR COOLANT LEAK (for Engine)  (See COOLING SYSTEM )
  39. INSPECT FOR REFRIGERANT LEAK  (See REPLACEMENT )
  40. PERFORM INITIALIZATION 
    NOTE: Some systems need initialization when disconnecting the cable from the negative battery terminal. (See INITIALIZATION )
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