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Air Conditioning Unit: Installation

  1. INSTALL BLOWER ASSEMBLY (w/o PTC Heater) 
    1. Install the blower assembly with the 3 screws.
    Fig 1: Identifying Blower Assembly Screws
    G06037544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL BLOWER ASSEMBLY (w/ PTC Heater) 
    1. Install the blower assembly with the 3 screws.
    2. Engage the quick heater connector and install the screw.
      Fig 2: Identifying Blower Assembly Screws
      G06037546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage each clamp.
      Fig 3: Identifying Blower Assembly Clamp
      G06015401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY 
    1. Engage the 2 claws to install the No. 3 air duct sub-assembly.
  4. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT 
    1. Engage the drain cooler hose.
    2. Temporarily tighten the air conditioning unit with the bolt and the nut.
    Fig 4: Identifying No. 3 Air Duct Sub-Assembly And Claws
    G06015357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 5: Identifying Air Conditioning Unit With Bolt And Nut
    G06037577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Install the instrument panel reinforcement assembly with the 7 bolts.

      Torque: <A> 

      24 N*m (245 kgf*cm, 18 ft.*lbf) 

      Fig 6: Identifying Instrument Panel Reinforcement Assembly With Bolts
      G06037578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector.
    3. Engage each clamp.
    4. Engage the wire harness and junction block with the 9 bolts.

      Torque: <A> 

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

      Fig 7: Identifying Instrument Panel Reinforcement Assembly Bolts, Connector And Claws
      G06037579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage each clamp and the wire harness.
    Fig 8: Identifying Instrument Panel Reinforcement Assembly Wire Harness Clamps
    G06037538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL AIR CONDITIONING UNIT 
    1. Install the 3 bolts.

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

      HINT:

      Tighten the bolts in the order shown in the illustration.

      Fig 9: Locating Air Conditioning Unit Bolts
      G06037581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

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

    3. Install the air conditioning unit with the nut.

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

    4. Engage the drain cooler hose.
    Fig 10: Identifying Air Conditioning Unit Nut And Bolt
    G06037542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL HEATER COVER (w/ Cover) 
    1. Engage the 4 claws to install the heater cover.
    Fig 11: Identifying Heater Cover Claws
    G06015346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the 2 bolts and the 2 nuts.
    2. Install the instrument panel brace sub-assembly with the 2 screws.

      Torque: Screw 

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

    3. Engage each clamp.
    4. Connect the connector.
    5. Install the 2 bolts.

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

      Fig 12: Identifying Instrument Panel Brace Sub-Assembly Bolts, Nuts And Screws
      G06037536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 13: Identifying Instrument Panel Brace Sub-Assembly Bolts, Claws And Connector
      G06037535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL THEFT WARNING ECU ASSEMBLY  (See INSTALLATION )
  10. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE 
    1. Install the center instrument panel to cowl brace with the 2 bolts.
    Fig 14: Locating Center Instrument Panel To Cowl Brace Bolts
    G06037534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY 
    1. Install the No. 1 air duct sub-assembly with the 2 nuts.

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

      Fig 15: Identifying No. 1 Air Duct Sub-Assembly Nuts
      G06037533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CENTER INSTRUMENT PANEL REGISTER CONNECTOR ASSEMBLY 
    1. Engage the 6 claws to install the center instrument panel register connector assembly.
    Fig 16: Identifying Center Instrument Panel Register Connector Assembly Claws
    G06037532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR NO. 1 AIR DUCT (w/ Rear Air Duct) 
    1. Engage the 4 claws to install the rear No. 1 air duct.
    Fig 17: Identifying Rear No. 1 Air Duct Claws
    G06037531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct) 
    1. Engage the 2 claws and install the rear No. 2 air duct.
      Fig 18: Identifying Rear No. 2 Air Duct Claws
      G06037530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the floor carpet and engage the clip.
    Fig 19: Identifying Floor Carpet And Clip
    G06037591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct) 
    1. Engage the 2 claws and install the rear No. 3 air duct.
      Fig 20: Identifying Rear No. 3 Air Duct Claws
      G06037528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the floor carpet and engage the clip.
      Fig 21: Identifying Floor Carpet And Clip
      G06037593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (See  INSTALLATION  ) 
  17. INSTALL POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
  18. INSTALL STEERING POST ASSEMBLY  (See INSTALLATION )
  19. TURN FRONT WHEELS TO FACE STRAIGHT AHEAD 
  20. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD)  (See INSTALLATION )
  21. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)  (See INSTALLATION )
  22. INSTALL STOP LIGHT SWITCH ASSEMBLY  (See INSTALLATION )
  23. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY  (See INSTALLATION )
  24. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT  (See INSTALLATION )
  25. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  26. INSTALL TRANSPONDER KEY AMPLIFIER (w/ Engine Immobilizer System)  (See INSTALLATION )
  27. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  28. INSTALL RADIO WIRE SUB-ASSEMBLY  (See INSTALLATION )
  29. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  (See INSTALLATION )
  30. INSTALL UPPER STEERING COLUMN COVER  (See INSTALLATION )
  31. INSTALL LOWER STEERING COLUMN COVER  (See INSTALLATION )
  32. CONNECT SHIFT LEVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  33. CONNECT SHIFT LEVER ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  34. INSTALL COWL SIDE TRIM BOARD LH  (See INSTALLATION )
  35. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  36. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover)  (See INSTALLATION )
  37. INSTALL COWL SIDE TRIM BOARD RH  (See INSTALLATION )
  38. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  39. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  40. INSTALL NO. 1 SWITCH HOLE BASE  (See INSTALLATION )
  41. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (for Manual Transaxle)  (See INSTALLATION )
  42. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (for Automatic Transaxle)  (See INSTALLATION )
  43. INSTALL FRONT NO. 1 CONSOLE BOX INSERT  (See INSTALLATION )
  44. INSTALL FRONT NO. 2 CONSOLE BOX INSERT  (See INSTALLATION )
  45. INSTALL FRONT CONSOLE BOX ASSEMBLY (for 2WD)  (See INSTALLATION )
  46. INSTALL FRONT CONSOLE BOX ASSEMBLY (for 4WD)  (See INSTALLATION )
  47. INSTALL CONSOLE BOX CARPET 
  48. INSTALL NO. 2 SWITCH HOLE BASE  (See INSTALLATION )
  49. INSTALL FRONT UPPER CONSOLE BOX  (See INSTALLATION )
  50. INSTALL AIR CONDITIONING PANEL ASSEMBLY (See  INSTALLATION  ) 
  51. INSTALL NAVIGATION ANTENNA CORD SUB-ASSEMBLY (w/ Navigation System)  (See )
  52. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System)  (See INSTALLATION )
  53. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System)  (See INSTALLATION )
  54. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  55. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY  (See INSTALLATION )
  56. INSTALL NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY  (See INSTALLATION )
  57. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  58. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  59. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  60. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  61. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  62. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY  (See INSTALLATION )
  63. INSTALL FRONT PILLAR GARNISH LH (w/o Curtain Shield Airbag)  (See INSTALLATION )
  64. INSTALL FRONT PILLAR GARNISH LH (w/ Curtain Shield Airbag)  (See INSTALLATION )
  65. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See INSTALLATION )
  66. INSTALL FRONT PILLAR GARNISH RH (w/o Curtain Shield Airbag)  (See INSTALLATION )
  67. INSTALL FRONT PILLAR GARNISH RH (w/ Curtain Shield Airbag)  (See INSTALLATION )
  68. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See INSTALLATION )
  69. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
  70. INSTALL METER HOOD SUB-ASSEMBLY  (See INSTALLATION )
  71. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  72. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  73. TURN FRONT WHEELS TO FACE STRAIGHT AHEAD 
  74. ADJUST SPIRAL CABLE  (See INSTALLATION )
  75. INSTALL STEERING WHEEL ASSEMBLY  (See INSTALLATION )
  76. INSTALL STEERING PAD  (See INSTALLATION )
  77. INSTALL LOWER NO. 3 STEERING WHEEL COVER  (See INSTALLATION )
  78. INSTALL LOWER NO. 2 STEERING WHEEL COVER  (See INSTALLATION )
  79. INSPECT STEERING WHEEL CENTER POINT 
  80. INSTALL HEATER OUTLET WATER HOSE 
    1. Install the water hose and attach the clip.
  81. INSTALL HEATER INLET WATER HOSE 
    1. Use the same procedure described for the heater outlet water hose.
    Fig 22: Locating Heater Outlet Water Hose Clip
    G06037526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. INSTALL LIQUID PIPE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the tube.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid pipe sub-assembly.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    3. Install the O-ring on the liquid pipe sub-assembly.
    4. Install the liquid pipe sub-assembly.
  83. INSTALL SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor oil: 

      ND-OIL 8 or equivalent 

    3. Install the O-ring on the suction hose sub-assembly.
    4. Move the hook connector in the direction indicated by the arrow in the illustration.
    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

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

      Fig 23: Identifying Suction Hose Sub-Assembly Bolt
      G06037595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. CHARGE WITH REFRIGERANT (See  REFRIGERANT  ) 
  85. ADD ENGINE COOLANT (for 2AZ-FE)  (See COOLANT )
  86. ADD ENGINE COOLANT (for 2ZR-FE)  (See COOLANT )
  87. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  88. INSPECT FOR COOLANT LEAK (for 2AZ-FE)  (See COOLING SYSTEM )
  89. INSPECT FOR COOLANT LEAK (for 2ZR-FE)  (See COOLING SYSTEM )
  90. INSPECT STEERING PAD  (See INSTALLATION )
  91. INSPECT SRS WARNING LIGHT 

    (See DIAGNOSIS SYSTEM )

  92. WARM UP ENGINE (See  REPLACEMENT  ) 
  93. INSPECT FOR REFRIGERANT LEAK (See  ON-VEHICLE INSPECTION   ) 
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