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INSTALLATION (To 8/2009): Installation

  1. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH 
    1. for Standard Bolt:
      1. Temporarily install the compressor and magnetic clutch and the bracket with the 4 bolts.
        Fig 1: Identifying 4 Bolts
        GTY286481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Bracket
    2. for Stud Bolt:
      1. Temporarily install the compressor and magnetic clutch and the bracket with the 2 stud bolts and 2 bolts.
        Fig 2: Identifying 2 Stud Bolts And 2 Bolts
        GTY271583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Bracket
        *2 Stud bolt
        *3 Bolt
  2. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. for Standard Bolt:
      1. Install the compressor and magnetic clutch with the 4 bolts.
        Fig 3: Identifying 4 Bolts
        GTY273768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

        NOTE:

        Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

    2. for Stud Bolt:
      1. Using a "TORX" socket wrench (E8), install the 2 stud bolts.
        Fig 4: Install The 2 Stud Bolts
        GTY274351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

      2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
        Fig 5: Identifying 2 Bolts And 2 Nuts
        GTY281032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

        NOTE:

        Tighten the bolts and nuts in the order shown in the illustration to install the compressor and magnetic clutch.

    3. Engage each clamp.
    4. Connect each connector.
  3. CONNECT SUCTION HOSE 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 compressor and magnetic clutch.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring onto the suction hose sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.
      Fig 6: Install The Suction Hose Sub-Assembly
      GTY272633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. CONNECT DISCHARGE HOSE 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 compressor and magnetic clutch.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring onto the discharge hose sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.
      Fig 7: Install The Discharge Hose Sub-Assembly
      GTY274259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  5. INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR 

    HINT: 

    Refer to the procedure for Install No. 2 Radiator Assembly. Refer to INSTALLATION - Step 1 .

  6. INSTALL COOLER CONDENSER ASSEMBLY  See step  1
  7. INSTALL UPPER RADIATOR SUPPORT  . Refer to INSTALLATION - Step 2
  8. CONNECT OUTLET OIL COOLER HOSE  . Refer to INSTALLATION - Step 8
  9. CONNECT INLET OIL COOLER HOSE  . Refer to INSTALLATION - Step 9
  10. CONNECT NO. 2 RADIATOR HOSE  . Refer to INSTALLATION - Step 10
  11. CONNECT NO. 1 RADIATOR HOSE  . Refer to INSTALLATION - Step 11
  12. INSTALL RADIATOR RESERVE TANK ASSEMBLY  . Refer to INSTALLATION - Step 12
  13. CONNECT DISCHARGE TUBE SUB-ASSEMBLY  See step  3
  14. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY  See step  4
  15. INSTALL BATTERY  . Refer to INSTALLATION - Step 71
  16. INSTALL NO. 1 AIR CLEANER INLET  . Refer to INSTALLATION - Step 72
  17. INSTALL NO. 2 AIR CLEANER INLET  . Refer to INSTALLATION - Step 73
  18. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY  See step  7
  19. INSTALL SMOG VENTILATION SENSOR (w/ Smog Ventilation Sensor)  See step  1
  20. INSTALL HIGH PITCHED HORN ASSEMBLY  . Refer to INSTALLATION - Step 1
  21. INSTALL HOOD LOCK ASSEMBLY  . Refer to INSTALLATION - Step 4
  22. INSTALL HOOD LOCK CONTROL CABLE COVER  . Refer to INSTALLATION - Step 5
  23. INSTALL LOW PITCHED HORN ASSEMBLY  . Refer to INSTALLATION - Step 1
  24. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)  . Refer to INSTALLATION - Step 1
  25. INSTALL FRONT BUMPER ASSEMBLY  . Refer to INSTALLATION - Step 1
  26. INSTALL HOOD CENTER CUSHION  . Refer to INSTALLATION - Step 2
  27. INSTALL V-RIBBED BELT  . Refer to INSTALLATION - Step 1
  28. INSTALL FRONT FENDER APRON SEAL RH  . Refer to INSTALLATION - Step 115
  29. INSTALL FRONT FENDER LINER RH  . Refer to INSTALLATION - Step 3
  30. INSTALL FRONT WHEEL RH  . Refer to INSTALLATION - Step 4
  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

  32. ADD ENGINE COOLANT  . Refer to REPLACEMENT - Step 8
  33. ADD WINDSHIELD WASHER FLUID (w/ Headlight Cleaner System)  . Refer to INSTALLATION - Step 2
  34. CHARGE WITH REFRIGERANT  See step  2
  35. WARM UP ENGINE  See step  3
  36. INSPECT FOR REFRIGERANT LEAK  See step  4
  37. INSPECT FOR COOLANT LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  38. INSPECT AUTOMATIC TRANSAXLE FLUID 

    for U660F: Refer to ADJUSTMENT

    for U660E: Refer to ADJUSTMENT

  39. INSTALL V-BANK COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 113
  40. INSTALL COOL AIR INTAKE DUCT SEAL  . Refer to INSTALLATION - Step 3
  41. INSTALL ENGINE ROOM SIDE COVER  . Refer to INSTALLATION - Step 4
  42. INSTALL ENGINE ROOM SIDE COVER LH  . Refer to INSTALLATION - Step 5
  43. INSTALL NO. 1 ENGINE UNDER COVER 
  44. INSPECT HOOD SUB-ASSEMBLY  . Refer to ON-VEHICLE INSPECTION - Step 1
  45. ADJUST HOOD SUB-ASSEMBLY  . Refer to INSTALLATION - Step 29
  46. PREPARE VEHICLE FOR FOG LIGHT AIM ADJUSTMENT  . Refer to ADJUSTMENT - Step 1
  47. PREPARE FOR FOG LIGHT AIMING  . Refer to ADJUSTMENT - Step 2
  48. INSPECT FOG LIGHT AIMING  . Refer to ADJUSTMENT - Step 3
  49. ADJUST FOG LIGHT AIMING  . Refer to ADJUSTMENT - Step 4
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