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Air Conditioning Unit: Installation

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL BLOWER ASSEMBLY 
    1. Install the blower assembly with the claw and screw

      Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 

    2. Connect the connector
  2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY  (See INSTALLATION  )
    Fig 1: Identifying Blower Assembly Claw And Screw
    G05755341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 AIR DUCT 
    1. Install the No 2 air duct with the screw

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

      Fig 2: Identifying No 2 Air Duct With Screw
      G05297842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Install the air conditioner unit assembly with the 3 bolts(1) and 2 screws.
      Fig 3: Identifying Air Conditioner Unit Assembly With Bolts And Screws
      G05755376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (BOLT 1) 

  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY 
    1. Driver seat side.
      Fig 4: Identifying Instrument Panel Reinforcement Assembly
      G05755377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a T40 "TORX" socket, install the instrument panel reinforcement with the 3 "TORX" bolts
    2. Passenger seat side
      1. Using a 12 mm hexagon wrench, install the instrument panel reinforcement with the 2 collars.

        Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      2. Using a T40 "TORX" socket, install the instrument panel reinforcement with the 2 "TORX" bolts

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

    3. Install the instrument panel reinforcement with the 3 bolts and nut(1).
      Fig 5: Identifying Instrument Panel Reinforcement With Bolts And Nut
      G05755378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (NUT 1) 

    4. Install the bolt and cap.
    5. Connect the 19 connectors and attach the 27 clamps.
    6. Install the 2 junction blocks with the 2 bolts and nut
      Fig 6: Identifying Junction Blocks With Bolts And Nut
      G05755336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL ID CODE BOX (IMMOBILIZER CODE ECU)  (See INSTALLATION )
  7. INSTALL DEFROSTER NOZZLE LOWER ASSEMBLY 
    1. Attach the 4 claws to install the defroster nozzle lower
    Fig 7: Identifying Clamps And Connectors
    G05755335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL SKID CONTROL ECU  (See INSTALLATION )
  9. INSTALL STEERING COLUMN ASSEMBLY  (See INSTALLATION )
  10. INSTALL BRAKE PEDAL RETURN SPRING  (See INSTALLATION )
  11. INSTALL NO. 1 AIR DUCT  (See INSTALLATION )
  12. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY  (See INSTALLATION )
  13. INSTALL INSTRUMENT PANEL STAY  (See INSTALLATION )
  14. INSTALL INSTRUMENT PANEL CLIP  (See INSTALLATION )
  15. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY  (See INSTALLATION )
  16. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY  (See INSTALLATION )
  17. INSTALL NO. 1 CONSOLE BOX DUCT  (See INSTALLATION )
  18. INSTALL NO. 2 CONSOLE BOX DUCT  (See INSTALLATION )
  19. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY (w/ Front Center Speaker)  (See INSTALLATION )
  20. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY  (See INSTALLATION )
  21. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY  (See INSTALLATION )
  22. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY  (See INSTALLATION )
  23. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  24. INSTALL FRONT PILLAR GARNISH RH 

    HINT:

    Use the same procedure for the RH side and LH side (See INSTALLATION )

  25. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  26. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY  (See INSTALLATION )
  27. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  28. INSTALL SIDE INSTRUMENT PANEL RH  (See INSTALLATION )
  29. INSTALL FRONT DOOR OPENING TRIM COVER RH 

    HINT.

    Use the same procedure for the RH side and LH side (See INSTALLATION )

  30. INSTALL FRONT DOOR SCUFF PLATE RH 

    HINT:

    Use the same procedure for the RH side and LH side (See INSTALLATION ).

  31. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
  32. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  33. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY  (See INSTALLATION )
  34. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  35. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  36. INSTALL SIDE INSTRUMENT PANEL LH  (See INSTALLATION )
  37. INSTALL FRONT DOOR OPENING TRIM COVER LH  (See INSTALLATION )
  38. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  39. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  (See INSTALLATION )
  40. INSTALL STEERING COLUMN COVER  (See INSTALLATION )
  41. ADJUST SPIRAL CABLE SUB-ASSEMBLY  (See INSTALLATION )
  42. INSTALL STEERING WHEEL ASSEMBLY  (See INSTALLATION )
  43. INSTALL STEERING PAD  (See INSTALLATION )
  44. INSTALL LOWER NO. 3 STEERING WHEEL COVER  (See INSTALLATION )
  45. INSTALL LOWER NO. 2 STEERING WHEEL COVER  (See INSTALLATION )
  46. INSTALL INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System)  (See INSTALLATION )
  47. INSTALL MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System)  (See INSTALLATION )
  48. INSTALL CENTER LOWER INSTRUMENT CLUSTER FINISH PANEL  (See INSTALLATION )
  49. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY  (See INSTALLATION )
  50. INSTALL CONSOLE BOX  (See INSTALLATION )
  51. INSTALL CONSOLE BOX REGISTER ASSEMBLY  (See INSTALLATION )
  52. INSTALL REAR ASH RECEPTACLE ASSEMBLY  (See INSTALLATION )
  53. INSTALL FRONT ASH RECEPTACLE ASSEMBLY  (See INSTALLATION )
  54. INSTALL CONSOLE PANEL SUB-ASSEMBLY  (See INSTALLATION )
  55. INSTALL UPPER NO. 2 CONSOLE PANEL GARNISH  (See INSTALLATION )
  56. INSTALL UPPER NO. 1 CONSOLE PANEL GARNISH  (See INSTALLATION )
  57. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY  (See INSTALLATION )
  58. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  59. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  60. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  61. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  62. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  63. INSTALL ROOF DRIP SIDE FINISH MOLDING LH  (See INSTALLATION )
  64. INSTALL ROOF DRIP SIDE FINISH MOLDING RH 

    HINT.

    Use the same procedure for the RH side and LH side (See INSTALLATION ).

  65. INSTALL FRONT UPPER FENDER PROTECTOR LH  (See INSTALLATION )
  66. INSTALL FRONT UPPER FENDER PROTECTOR RH 

    HINT.

    Use the same procedure for the RH side and LH side (See INSTALLATION ).

  67. INSTALL HEATER WATER INLET HOSE 
    1. Install the water hose and attach the clip.
  68. INSTALL HEATER WATER OUTLET HOSE 

    HINT

    Use the same procedure for the water hose inlet.

  69. INSTALL COOLER REFRIGERANT LIQUID PIPE A 
    1. Remove the vinyl tape attached to the pipe.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe A.

      Compressor oil: 

      ND-OIL 8 or equivalent 

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

      Compressor oil: 

      ND-OIL 8 or equivalent 

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

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

      6. Fig 8: Identifying Pipe Joints Into Fitting Holes
      G05755381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  72. CHARGE REFRIGERANT  (See REPLACEMENT  )
  73. WARM UP ENGINE  (See REPLACEMENT  )
  74. INSPECT FOR REFRIGERANT LEAK  (See REFRIGERANT LINE  )
  75. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  76. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  77. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
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