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Air Conditioning Unit: Installation

  1. INSTALL AIR CONDITIONING UNIT 
    1. Install the air conditioning unit with the 3 screws.
      Fig 1: Identifying Air Conditioning Unit Screws
      G05401720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Engage the claw and install the air conditioning amplifier as shown in the illustration.
      2. Fig 2: Identifying Air Conditioning Amplifier Screw
      G05401721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the screw.
  3. INSTALL INSTRUMENT PANEL REINFORCEMENT (for Manual Transaxle) 
    1. Temporarily tighten the air conditioning unit with the 3 screws.
      2. Fig 3: Identifying Air Conditioning Unit Screws
      G05401722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the instrument panel reinforcement and the air conditioning unit with the 9 bolts.

      Torque: 24 N*m (241 kgf*cm, 17 ft.*lbf) for Bolt A 

      Fig 4: Identifying Instrument Panel Reinforcement Bolts
      G05401723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 screws, 3 bolts and nut in the sequence shown in the illustration.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) for screw 9.8 N*m (100 kgf*cm, 87 in.*lbf) for nut 9.8 N*m (100 kgf*cm, 87 in.*lbf) for bolt 

      Fig 5: Identifying Tightening Sequence Of Bolts
      G05401724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL INSTRUMENT PANEL REINFORCEMENT (for Automatic Transaxle) 
    1. Temporarily tighten the air conditioning unit with the 3 screws.
      2. Fig 6: Identifying Air Conditioning Unit Screws
      G05401725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the instrument panel reinforcement and the air conditioning unit with the 8 bolts.
      Fig 7: Identifying Instrument Panel Reinforcement And Air Conditioning Unit Bolts
      G05401726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 screws, 3 bolts and nut in the sequence shown in the illustration.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) for screw A 

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

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

      Fig 8: Identifying Tightening Sequence Of Bolts
      G05401727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL INSTRUMENT PANEL WIRE 
    1. Install the wire harness with the clamps and connectors.
      Fig 9: Locating Connectors And Clamps
      G05401728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ground wire with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      Fig 10: Locating Ground Wire Bolt
      G05401729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connectors and install the wire harness.
      Fig 11: Identifying Connectors
      G05401730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the connector holder with the bolt.

      Torque: 3.2 N*m (33 kgf*cm, 28 in.*lbf) 

      Fig 12: Locating Connector Holder Bolt
      G05401731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL MAIN BODY ECU 
    1. Install the main body ECU with the 2 bolts.

      Torque: 3.2 N*m (33 kgf*cm, 28 in.*lbf) 

      Fig 13: Locating Main Body ECU Bolts
      G05401732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 5 connectors and the 3 clamps.
      Fig 14: Locating Main Body ECU Connectors
      G05401733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT DRAIN COOLER HOSE 
    1. Install the drain hose into the position shown in the illustration.
      NOTE:
      • Install the drain hose with its UP mark facing upward, within the 90 degree range shown in the illustration.
      • Install the drain hose without twisting it.
        Fig 15: Identifying Installation Position Of Drain Cooler Hose
        G05401734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REAR NO. 3 AIR DUCT 
    1. Engage the 4 claws and install the air duct.
      Fig 16: Identifying Rear No 3 Air Duct Claws
      G05401735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the instrument panel brace with the bolt, screw and nut.

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

    2. Install the PTC heater wire with the bolt.

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

      Fig 17: Locating Instrument Panel Brace Bolts
      G05401736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 3 clamps.
  10. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 4 claws and install the air duct.
      Fig 18: Identifying Rear No 2 Air Duct Claws
      G05401737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 2 claws and install the air duct.
      Fig 19: Identifying Rear No 1 Air Duct Claws
      G05401738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL DEFROSTER NOZZLE ASSEMBLY 
    1. Engage the 5 claws and install the defroster nozzle.
      Fig 20: Identifying Defroster Nozzle Claws
      G05401739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY 
    1. Engage the 3 claws and install the heater to register duct.
      2. Fig 21: Identifying Heater And Register Duct Claws
      G05401740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL STEERING COLUMN ASSEMBLY  (See INSTALLATION )
  15. INSTALL BRAKE PEDAL SUPPORT  (See INSTALLATION )
  16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS  (See INSTALLATION )
  17. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY 
    1. Align the matchmarks and install the sliding yoke onto the steering gear assembly with bolt B.

      Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) 

      Fig 22: Identifying Matchmarks On Sliding Yoke Of Steering Intermediate Shaft And Power Steering Link
      G05401741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten bolt A.

      Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) 

  18. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  19. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT  (See INSTALLATION )
  20. CONNECT POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
  21. INSTALL COMBINATION SWITCH ASSEMBLY  (See INSTALLATION )
  22. INSTALL STEERING COLUMN UPPER COVER  (See INSTALLATION )
  23. INSTALL STEERING COLUMN LOWER COVER  (See INSTALLATION )
  24. INSTALL STEERING WHEEL ASSEMBLY  (See INSTALLATION )
  25. INSTALL STEERING PAD  (See INSTALLATION )
  26. INSTALL LOWER INSTRUMENT PANEL  (See INSTALLATION )
  27. CONNECT ANTENNA CORD SUB-ASSEMBLY  (See INSTALLATION )
  28. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY  (See INSTALLATION )
  29. INSTALL NO. 1 RADIO BRACKET  (See INSTALLATION )
  30. INSTALL NO. 2 RADIO BRACKET  (See INSTALLATION )
  31. INSTALL INSTRUMENT PANEL BOX  (See INSTALLATION )
  32. INSTALL INSTRUMENT PANEL UNDER TRAY  (See INSTALLATION )
  33. INSTALL FRONT CONSOLE BOX  (See INSTALLATION )
  34. CONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY  (See INSTALLATION  )
  35. CONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY  (See INSTALLATION  )
  36. CONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY  (See INSTALLATION  )
  37. INSTALL AIR CONDITIONING PANEL ASSEMBLY  (See INSTALLATION  )
  38. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY  (See INSTALLATION )
  39. INSTALL CONSOLE BOX CARPET  (See INSTALLATION )
  40. INSTALL REAR CONSOLE BOX COVER  (See INSTALLATION )
  41. INSTALL UPPER CONSOLE PANEL  (See INSTALLATION )
  42. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  43. INSTALL COWL SIDE TRIM BOARD RH  (See INSTALLATION )
  44. INSTALL COWL SIDE TRIM BOARD LH  (See INSTALLATION )
  45. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  46. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  47. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  48. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  49. INSTALL UPPER INSTRUMENT PANEL  (See INSTALLATION )
  50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  51. INSTALL INSTRUMENT CLUSTER FINISH PANEL RETAINER  (See INSTALLATION )
  52. INSTALL INSTRUMENT CLUSTER FINISH CENTER PANEL SUB-ASSEMBLY  (See INSTALLATION )
  53. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
  54. INSTALL INSTRUMENT CLUSTER FINISH PANEL  (See INSTALLATION )
  55. INSTALL FRONT PILLAR GARNISH RH  (See INSTALLATION )
  56. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  57. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See INSTALLATION )
  58. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See INSTALLATION )
  59. CONNECT HEATER WATER INLET HOSE A 
    1. Install the heater water inlet hose onto the heater unit.
      NOTE: Perform the installation with the hose clip and mark at the correct angle.
      Fig 23: Connecting Heater Water Inlet Hose A
      G05401742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Install the heater water outlet hose onto the heater unit.
      NOTE: Perform the installation with the hose clip and mark at the correct angle.
      Fig 24: Connecting Heater Water Outlet Hose A
      G05401743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL LIQUID TUBE SUB-ASSEMBLY 
    1. Remove the vinyl tape from liquid tube and the connecting portion of the unit.
    2. Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the liquid tube.

      Compressor oil: 

      ND-OIL8 or equivalent 

    3. Install the O-ring onto the liquid tube.
    4. Connect the liquid tube to the unit.
  62. INSTALL SUCTION TUBE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction tube and the connecting part of the unit.
    2. Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the suction tube.

      Compressor oil: 

      ND-OIL8 or equivalent 

    3. Install the O-ring onto the suction tube.
    4. Turn the hook connector in the direction indicated by the arrow in the illustration.
      5. Fig 25: Installing Suction Tube
      G05401744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert the pipe joints securely into the fitting holes and tighten the bolt.

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

  63. INSTALL OUTER COWL TOP PANEL  (See INSTALLATION )
  64. INSTALL FRONT AIR SHUTTER SEAL RH  (See INSTALLATION )
  65. INSTALL FRONT WIPER MOTOR AND LINK  (See INSTALLATION )
  66. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
  67. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  68. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
  69. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  70. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  71. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  72. ADD ENGINE COOLANT  (See REPLACEMENT )
  73. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  74. INSPECT SRS WARNING LIGHT 

    (See DIAGNOSIS SYSTEM )

  75. CHARGE REFRIGERANT  (See REFRIGERANT LINE  )
  76. WARM UP ENGINE  (See REPLACEMENT  )
  77. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  78. INSPECT FOR REFRIGERANT LEAK  (See REPLACEMENT  )
  79. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
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