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Air Conditioning Unit: Installation

  1. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Engage the 4 claws and install the lower defroster nozzle.
      Fig 1: Identifying Lower Defroster Nozzle Claws
      G05112819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL HEATER TO REGISTER DUCT ASSEMBLY 
    1. Engage the 4 claws and install the heater to register duct.
      Fig 2: Identifying Heater To Register Duct Claws
      G05112818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Install the air conditioning unit with the 2 screws as shown in the illustration.
      2. Fig 3: Identifying Air Conditioning Unit With Screws
      G05112847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL INSTRUMENT PANEL REINFORCEMENT 
    1. Provisionally install the air conditioning unit assembly.
    2. Insert the bracket hook into the holes of the reinforcement bracket, and provisionally install the reinforcement.
    3. Install the instrument panel reinforcement with the 7 bolts.
      4. Fig 4: Identifying Instrument Panel Reinforcement Bolts
      G05112848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 caps.
    5. Install the 5 bolts.
      NOTE: Tighten the bolts in the sequence order shown in the illustration to install the air conditioner unit assembly.

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

      Fig 5: Identifying Tightening Sequence Of Bolts And Nuts
      G05112849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 2 nuts.

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

    7. Engage the clamps.
      Fig 6: Identifying Instrument Panel Reinforcement Clamps
      G05112814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the connectors.
    9. Connect the wire harness with the 3 bolts and 5 nuts.
      Fig 7: Identifying Wire Harness Bolts And Nuts
      G05112813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.3 N*m (74 kgf*cm, 65 in.*lbf) for nut 

  5. INSTALL COOLER UNIT DRAIN HOSE 
    1. Install the cooler unit drain hose.
      Fig 8: Identifying Cooler Unit Drain Hose
      G05112812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL MAIN BODY ECU (DRIVER SIDE J/B) 
    1. Install the main body ECU with the 2 nuts.

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

      Fig 9: Identifying Main Body ECU With Nuts
      G05112811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL INSTRUMENT PANEL SIDE BRACKET 
    1. Install the instrument panel side bracket with the bolt.

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

      2. Fig 10: Identifying Instrument Panel Side Bracket Bolt
      G05112810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL STEERING COLUMN ASSEMBLY  (See INSTALLATION )
  9. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY 
    1. Align the matchmarks on the steering column assembly and the steering intermediate shaft assembly.
      2. Fig 11: Identifying Matchmarks On Steering Column Assembly And Steering Intermediate Shaft
      G05112809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the steering intermediate shaft assembly and thrust stopper onto the steering column assembly with the bolt.

      Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

  10. INSTALL STEERING COLUMN HOLE COVER  (See INSTALLATION )
  11. INSTALL ECM  (See INSTALLATION )
  12. INSTALL NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET 
    1. for LH side:
      1. Install the instrument panel brace mounting bracket with the bolt and nut.
        Fig 12: Identifying Instrument Panel Brace Mounting Bracket Bolt And Nut (LH Side)
        G05112807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for RH side:
      1. Install the instrument panel brace mounting bracket with the bolt and nut.
        Fig 13: Identifying Instrument Panel Brace Mounting Bracket Bolt And Nut (RH Side)
        G05112808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 1 AIR DUCT 
    1. Engage the 3 claws and install the air duct.
      Fig 14: Identifying No. 1 Air Duct Claws
      G05112805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 2 AIR DUCT 
    1. Engage the 3 claws and install the air duct.
      Fig 15: Identifying No. 2 Air Duct Claws
      G05112806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 6 claws and 3 clamps and install the air duct.
      Fig 16: Identifying No. 1 Rear Air Duct Claws And Clamps
      G05112803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 6 claws and 3 clamps and install the air duct.
      Fig 17: Identifying No. 2 Rear Air Duct Claws And Clamps
      G05112804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 1 HEATER TO REGISTER DUCT 
    1. Install the heater to register duct with the screw.
      Fig 18: Identifying No. 1 Heater To Register Duct Screw
      G05112801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL NO. 2 HEATER TO REGISTER DUCT 
    1. Install the heater to register duct with the screw.
      2. Fig 19: Identifying No. 2 Heater To Register Duct Screw
      G05112863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  20. CONNECT PASSENGER AIRBAG CONNECTOR  (See INSTALLATION )
  21. INSTALL INSTRUMENT PANEL FINISH PANEL END LH  (See INSTALLATION )
  22. INSTALL ASSIST GRIP RETAINER RH  (See INSTALLATION )
  23. INSTALL ASSIST GRIP RETAINER LH  (See INSTALLATION )
  24. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY  (See INSTALLATION )
  25. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See INSTALLATION )
  26. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See INSTALLATION )
  27. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY  (See INSTALLATION )
  28. INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH  (See INSTALLATION )
  29. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  30. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
  31. INSTALL INSTRUMENT CLUSTER FINISH PANEL  (See INSTALLATION )
  32. INSTALL LOWER INSTRUMENT PANEL LH  (See INSTALLATION )
  33. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LH  (See INSTALLATION )
  34. INSTALL INSTRUMENT PANEL FINISH PLATE  (See INSTALLATION )
  35. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY  (See INSTALLATION )
  36. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY  (See INSTALLATION )
  37. INSTALL INSTRUMENT LOWER COVER SUB-ASSEMBLY  (See INSTALLATION )
  38. INSTALL CONSOLE UPPER PANEL NO. 1 GARNISH  (See INSTALLATION )
  39. INSTALL FRONT CONSOLE BOX  (See INSTALLATION )
  40. INSTALL BOX BOTTOM MAT  (See INSTALLATION )
  41. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY  (See INSTALLATION )
  42. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission)  (See INSTALLATION )
  43. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for 4WD)  (See INSTALLATION )
  44. INSTALL PARKING BRAKE HOLE COVER SUB-ASSEMBLY  (See INSTALLATION )
  45. INSTALL RADIO RECEIVER ASSEMBLY  (See INSTALLATION )
  46. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY  (See INSTALLATION )
  47. INSTALL INSTRUMENT PANEL GARNISH LH  (See INSTALLATION )
  48. INSTALL INSTRUMENT PANEL GARNISH RH  (See INSTALLATION )
  49. INSTALL FRONT PILLAR GARNISH RH  (See INSTALLATION )
  50. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  51. INSTALL ASSIST GRIP ASSEMBLY  (See INSTALLATION )
  52. INSTALL ASSIST GRIP PLUG  (See INSTALLATION )
  53. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See INSTALLATION )
  54. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See INSTALLATION )
  55. INSTALL COWL SIDE TRIM BOARD RH  (See INSTALLATION )
  56. INSTALL COWL SIDE TRIM BOARD LH  (See INSTALLATION )
  57. INSTALL FOOTREST CLIP  (See INSTALLATION )
  58. INSTALL FRONT FLOOR FOOTREST  (See INSTALLATION )
  59. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  60. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  61. INSTALL COMBINATION SWITCH ASSEMBLY  (See INSTALLATION )
  62. INSTALL UPPER STEERING COLUMN COVER  (See INSTALLATION )
  63. INSTALL LOWER STEERING COLUMN COVER  (See INSTALLATION )
  64. INSTALL STEERING WHEEL ASSEMBLY  (See INSTALLATION )
  65. INSTALL STEERING PAD  (See INSTALLATION )
  66. INSTALL LOWER NO. 2 STEERING WHEEL COVER  (See INSTALLATION )
  67. INSTALL LOWER NO. 3 STEERING WHEEL COVER  (See INSTALLATION )
  68. 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 as shown in the illustration.
      Fig 20: Identifying Heater Water Outlet Hose Onto Heater Unit
      G05112864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. CONNECT HEATER INLET WATER HOSE 
    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 as shown in the illustration.
      Fig 21: Identifying Heater Water Inlet Hose Onto Heater Unit
      G05112865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL COOLER REFRIGERANT LIQUID PIPE A 
    Fig 22: Identifying Correct Position Of Cooler Refrigerant Liquid Pipe Clamp
    G05580161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the vinyl tape from liquid tube A 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 pipe.

      Compressor oil: 

      ND-OIL8 or the equivalent 

    3. Install the O-ring onto the liquid pipe.
    4. Install the liquid and piping clamp.

      HINT:

      After connection, check the claw fitting of the piping clamp.

  71. INSTALL COOLER REFRIGERANT SUCTION PIPE A 

    HINT:

    Connection procedure of the suction pipe is the same as for the liquid pipe.

  72. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
  73. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
  74. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  75. INSTALL FRONT FENDER SIDE PANEL UPPER LH  (See INSTALLATION )
  76. INSTALL FRONT FENDER SIDE PANEL UPPER RH  (See INSTALLATION )
  77. INSTALL ANTENNA ORNAMENT  (See INSTALLATION )
  78. INSTALL ROOF ANTENNA POLE SUB-ASSEMBLY  (See INSTALLATION )
  79. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  80. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (CENTER SIDE)  (See INSTALLATION )
  81. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  82. INSTALL WINDSHIELD WIPER ARM COVER  (See INSTALLATION )
  83. ADD ENGINE COOLANT  (See REPLACEMENT )
  84. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 

  85. CHECK SRS WARNING LIGHT 

    DIAGNOSIS SYSTEM

  86. CHARGE REFRIGERANT  (See REPLACEMENT  )
  87. WARM UP ENGINE  (See REPLACEMENT  )
  88. CHECK FOR ENGINE COOLANT LEAK  (See REPLACEMENT )
  89. CHECK FOR REFRIGERANT LEAK  (See REPLACEMENT  )
  90. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
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