LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2008 >> FJ Cruiser RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 200 (Air Conditioning) >> AIR CONDITIONING UNIT (for Hatchback) >> Installation

AIR CONDITIONING UNIT (for Hatchback): Installation

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL AIR CONDITIONING UNIT 
    1. Install the air conditioning unit with the 3 screws.
      Fig 1: Identifying Screws For Air Conditioning Unit
      G04829702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 
    1. Install the air conditioning amplifier with the screw.
      Fig 2: Locating Screw For Air Conditioning Amplifier
      G04829615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL INSTRUMENT PANEL REINFORCEMENT 
    1. Provisionally tighten the air conditioning unit with the 3 screws.
      Fig 3: Locating Air Conditioning Unit Screws
      G04829700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector and the 3 clamps.
    3. Install the instrument panel reinforcement and the air conditioning unit with the 9 bolts.
      Fig 4: Locating Connector Clamps
      G04829699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 5: Identifying Instrument Panel Reinforcement Bolts
      G04829698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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 6: Identifying Screws, Bolts And Nut
      G04829734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the wire harness with the clamps and connectors.
      Fig 7: Locating Connectors And Clamps
      G04829611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the clamps.
      Fig 8: Identifying Clamps
      G04829695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the connectors.
      Fig 9: Locating Connector
      G04829694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the ground wire with the bolt.

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

      Fig 10: Identifying Bolt For Ground Wire
      G04829693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. 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 11: Locating Drain Hose Position
      G04829649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL CONNECTOR NO. 2 HOLDER 
    1. Connect the connectors and install the wire harness.
      Fig 12: Identifying Connector No. 2 Holder
      G04829691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the connector holder with the bolt.

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

      Fig 13: Identifying Connector No. 2 Holder
      G04829690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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 14: Locating Main Body ECU Bolts
      G04829604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 5 connectors and the 3 clamps.
      Fig 15: Locating Connectors And Clamps
      G04829688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the instrument panel brace with the 2 bolts, screw and nut.

      Torque: 9.8 N*m (100 kgf*cm, 87 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 

    2. Engage the clamp.
      Fig 16: Locating Instrument Panel Brace Bolts
      G04829687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR NO. 3 AIR DUCT (for Cold Area Specification Vehicles) 
    1. Engage the 4 claws and install the air duct.
      Fig 17: Locating Claws For No. 3 Air Duct
      G04829601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REAR NO. 1 AIR DUCT (for Cold Area Specification Vehicles) 
    1. Engage the 2 claws and install the air duct.
      Fig 18: Locating Claws For No. 1 Air Duct
      G04829600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR NO. 2 AIR DUCT (for Cold Area Specification Vehicles) 
    1. Engage the 4 claws and install the air duct.
  10. INSTALL DEFROSTER NOZZLE ASSEMBLY 
    1. Engage the 5 claws and install the defroster nozzle.
    2. Connect the clamps and connectors and install the wire harness.
      Fig 19: Identifying Claws For Air Duct
      G04829599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 20: Locating Claws For Defroster Nozzle
      G04829683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL STEERING COLUMN ASSEMBLY  (See INSTALLATION )
  12. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  13. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (for Manual Transaxle)  (See INSTALLATION )
  14. INSTALL BRAKE PEDAL (for Automatic Transaxle)  (See INSTALLATION )
  15. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY 
    1. Align the matchmarks and install the sliding yoke onto the power steering assembly with bolt B.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

    2. Tighten bolt A.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  16. INSTALL COLUMN HOLE COVER SILENCER SHEET  INSTALLATION 
  17. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT  INSTALLATION 
    Fig 21: Identifying Steering Yoke Bolt Matchmarks
    G04829596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. CONNECT POWER STEERING ECU ASSEMBLY  INSTALLATION 
  19. INSTALL COMBINATION SWITCH ASSEMBLY  INSTALLATION 
  20. INSTALL STEERING COLUMN COVER  INSTALLATION 
  21. INSTALL STEERING WHEEL ASSEMBLY  INSTALLATION 
  22. INSTALL STEERING PAD  (See INSTALLATION )
  23. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  24. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY  (See INSTALLATION )
  25. CONNECT ANTENNA CORD SUB-ASSEMBLY  (See INSTALLATION )
  26. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY  (See INSTALLATION )
  27. INSTALL INSTRUMENT PANEL BOX  (See INSTALLATION )
  28. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER  (See INSTALLATION )
  29. INSTALL CONSOLE BOX ASSEMBLY REAR  (See INSTALLATION )
  30. INSTALL CONSOLE BOX CARPET  (See INSTALLATION )
  31. INSTALL CONSOLE BOX REAR COVER  (See INSTALLATION )
  32. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  33. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  34. INSTALL COWL SIDE TRIM BOARD RH  (See INSTALLATION )
  35. INSTALL COWL SIDE TRIM BOARD LH  (See INSTALLATION )
  36. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH  (See INSTALLATION )
  37. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY RH  (See INSTALLATION )
  38. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  39. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  40. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  41. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  42. INSTALL NO. 1 SWITCH HOLE BASE  (See INSTALLATION )
  43. INSTALL FRONT PILLAR GARNISH RH  (See INSTALLATION )
  44. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  45. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See INSTALLATION )
  46. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See INSTALLATION )
  47. CONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (See INSTALLATION  )
  48. CONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (See INSTALLATION  )
  49. CONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (See INSTALLATION  )
  50. INSTALL AIR CONDITIONER PANEL SUB-ASSEMBLY (See INSTALLATION  )
  51. INSTALL RADIO TUNER OPENING COVER (w/o Radio Receiver) 
    1. Install the radio tuner opening cover with the 4 bolts.
  52. INSTALL RADIO RECEIVER ASSEMBLY  (See INSTALLATION )
  53. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY CENTER (See INSTALLATION  )
  54. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
    Fig 22: Identifying Radio Tuner Opening Cover Bolts
    G04829681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL INSTRUMENT CLUSTER FINISH PANEL  (See INSTALLATION )
  56. INSTALL INSTRUMENT PANEL FINISH PANEL END RH  (See INSTALLATION )
  57. INSTALL INSTRUMENT PANEL FINISH PANEL END LH  (See INSTALLATION )
  58. 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: Identifying Hose Clip And Mark Angle For Heater Water Inlet Hose
      G04829661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. 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.
  60. 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 liquid tube.

      Compressor oil: ND-OIL8 or the equivalent 

    3. Install the O-ring onto liquid tube.
    4. connect liquid tube to the unit.
      Fig 24: Identifying Hose Clip And Mark Angle For Heater Water Outlet Hose
      G04829662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. 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 suction tube.

      Compressor oil: ND-OIL8 or the equivalent 

    3. Install the O-ring onto the suction tube.
    4. Move the hook connector in the direction indicated by the arrow in the illustration.
    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) 

  62. INSTALL COWL TOP PANEL OUTER  INSTALLATION 
  63. INSTALL NO. 2 COWL TO REGISTER DUCT SUB-ASSEMBLY  INSTALLATION 
  64. INSTALL FRONT WIPER MOTOR AND LINK  (See INSTALLATION )
    Fig 25: Locating Tube Joints Into Fitting Holes
    G04829663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
  66. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  67. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
  68. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  69. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  70. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  71. ADD ENGINE COOLANT  (See REPLACEMENT )
  72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm) 

  73. CHECK SRS WARNING LIGHT 

    RS-31

  74. CHARGE REFRIGERANT (See REPLACEMENT  )
  75. WARM UP ENGINE (See REPLACEMENT  )
  76. CHECK FOR ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  77. CHECK FOR REFRIGERANT LEAK (See REPLACEMENT  )
  78. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
scientia non olet · About LEMON Manuals