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Air Conditioning Unit: Installation

  1. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY 
    1. Temporarily tighten the air conditioning radiator with the 2 nuts.
      Fig 1: Identifying Air Conditioning Radiator With Nuts
      G05540684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 connectors.
  2. INSTALL BLOWER ASSEMBLY  (See INSTALLATION  )
    Fig 2: Locating Connectors
    G05540683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Fully tighten the air conditioner unit with the bolt, screw and 2 nuts.

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

      NOTE: Tighten in the order indicated in the illustration.
      Fig 3: Identifying Tightening Sequence Of Bolts
      G05540717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL AIR DUCT 
    1. Attach the 2 claws and install the air duct.
      Fig 4: Identifying Air Duct With Claws And Screw
      G05540682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the screw.
    3. Connect the connector and install the connector to the air duct.
      Fig 5: Locating Air Duct Connector
      G05540681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the instrument panel brace with the bolt and nut.
      Fig 6: Identifying Instrument Panel Brace With Bolt And Nut
      G05540680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the antenna cord and attach the clamp.
    3. Install the wire harness and attach the 2 clamps.
      Fig 7: Identifying Antenna Cord Sub-Assembly And Wire Harness With Clamps
      G05540679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 
    1. Install the instrument panel to cowl brace with the 3 bolts and nut.
      Fig 8: Identifying Instrument Panel To Cowl Brace With Bolts And Nut
      G05540678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the 2 claws to install the connector.
      Fig 9: Identifying Claws And Connector
      G05540677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the wire harness and attach the 2 clamps.
      Fig 10: Identifying Clamps And Wire Harness
      G05540676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the ground wire with the bolt.
      Fig 11: Identifying Ground Wire With Bolt
      G05540675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the wire harness and attach the 4 clamps.
      Fig 12: Identifying Wire Harness And Clamps
      G05540674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Reposition the floor carpet and install the clip.
      Fig 13: Locating Clip
      G05540727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL INSTRUMENT PANEL TO COWL BRACE CENTER 
    1. Install the instrument panel to cowl brace center with the 2 bolts.
      Fig 14: Identifying Instrument Panel To Cowl Brace Center With Bolts
      G05540672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL DEFROSTER NOZZLE ASSEMBLY LOWER 
    1. Attach the 2 claws and install the defroster nozzle assembly lower.
      Fig 15: Identifying Defroster Nozzle Assembly Lower With Claws
      G05540671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 3 HEATER TO REGISTER DUCT 
    1. Attach the 2 claws and install the heater to register duct.
    2. Install the 2 clips.
  10. INSTALL ECM  (See INSTALLATION )
  11. INSTALL INSTRUMENT PANEL LOWER ASSEMBLY 
    1. Install the instrument panel lower assembly (see INSTALLATION ).
  12. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER 
    1. Install the instrument panel sub-assembly upper (see INSTALLATION ).
      Fig 16: Identifying No. 3 Heater To Register Duct With Clips And Claws
      G05540670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT HEATER WATER OUTLET HOSE 
    1. Connect the water hose and attach the clip.
  14. CONNECT HEATER WATER INLET HOSE 

    HINT:

    Use the same procedures described for the water hose.

    Fig 17: Identifying Heater Water Outlet Hose And Heater Water Intake Hose
    G05540669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL COOLER REFRIGERANT LIQUID PIPE 
    1. Remove the attached vinyl tape from the pipe.
    2. Sufficiently apply compressor oil to new 2 O-rings and the fitting surface of the cooler refrigerant liquid pipe A.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    3. Install the 2 O-rings on the cooler refrigerant liquid pipe.
    4. Install the cooler refrigerant liquid pipe and piping clamp.

      HINT:

      After the connection, check that the claw of the piping clamp is engaged.

      Fig 18: Identifying Correct And Incorrect Installation Positions Cooler Refrigerant Liquid Pipe
      G05540732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE 
    1. Remove the attached vinyl tape from the pipe.
    2. Sufficiently apply compressor oil to new 2 O-rings and the fitting surface of the cooler refrigerant suction hose.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    3. Install the 2 O-rings on the cooler refrigerant suction hose.
    4. Install the cooler refrigerant suction hose and the piping clamp.

      HINT:

      After the connection, check that the claw of the piping clamp is engaged.

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  18. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  19. INSPECT SRS WARNING LIGHT 
    1. Check the SRS warning light (see DIAGNOSIS SYSTEM ).
  20. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  21. CHARGE REFRIGERANT  (See REPLACEMENT  )
  22. WARM UP ENGINE  (See REPLACEMENT  )
  23. INSPECT FOR ENGINE COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  24. INSPECT FOR REFRIGERANT LEAK  (See REPLACEMENT  )