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AIR CONDITIONING UNIT (for Sedan): Installation

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  1. INSTALL AIR CONDITIONING UNIT 
    1. Install the air conditioning unit with the 3 screws.
      Fig 1: Identifying Screws For Air Conditioning Unit
      G04829616Courtesy 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.
    2. Install the instrument panel reinforcement and the air conditioning unit with the 9 bolts.
      Fig 3: Identifying Screws For Air Conditioning Unit
      G04829614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 4: Identifying Instrument Panel Reinforcement Bolts And Nuts
      G04829613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 screws, 3 bolts and the 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 5: Identifying Instrument Panel Reinforcement Screws
      G04829644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the wire harness with the clamps and connect the connectors.
      Fig 6: Locating Connectors And Clamps
      G04829611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the clamps.
      Fig 7: Identifying Clamps
      G04829610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the ground wire with the bolt.

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

      Fig 8: Locating Ground Wire Bolt
      G04829608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the ground wire with the bolt, (for Cold area specification vehicles)

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 9: Locating Ground Wire Bolt
      G04829609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. 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 10: 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 11: Separating Connector Holder
      G04829606Courtesy 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 12: Locating Connector No. 2 Holder
      G04829605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL MAIN BODY ECU (DRIVER SIDE J/B) 
    1. Install the main body ECU with the 2 bolts.

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

      Fig 13: Locating Main Body ECU Bolts
      G04829604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 5 connectors and the 3 clamps.
      Fig 14: Identifying Main Body ECU Connectors And Clamps
      G04829603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the instrument panel brace with the bolt, 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 15: Locating Instrument Panel Brace Screw And Nut
      G04829602Courtesy 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 16: 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 17: 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.
      Fig 18: Identifying Claws For Rear No. 2 Air Duct
      G04829657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DEFROSTER NOZZLE ASSEMBLY 
    1. Engage the 5 claws and install the defroster nozzle.
    2. Connect the 3 clamps and connector and install the wire harness.
      Fig 19: Identifying Connector And Clamps
      G04829598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL HEATER TO REGISTER DUCT ASSEMBLY 
    1. Engage the 3 claws and install the heater to register duct.
  12. INSTALL STEERING COLUMN ASSEMBLY  (See INSTALLATION )
  13. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  14. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (for Manual Transaxle)  (See INSTALLATION )
  15. INSTALL BRAKE PEDAL (for Automatic Transaxle)  (See INSTALLATION )
    Fig 20: Identifying Claws For Heater To Register Duct
    G04829597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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) 

      Fig 21: Identifying Steering Yoke Bolt Matchmarks
      G04829596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  18. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT 
  19. CONNECT POWER STEERING ECU  (See INSTALLATION )
  20. INSTALL COMBINATION SWITCH ASSEMBLY  (See INSTALLATION )
  21. INSTALL STEERING COLUMN COVER  (See INSTALLATION )
  22. INSTALL STEERING WHEEL ASSEMBLY  (See INSTALLATION )
  23. INSTALL STEERING PAD  (See INSTALLATION )
  24. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  25. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY  (See INSTALLATION )
  26. CONNECT ANTENNA CORD SUB-ASSEMBLY  (See INSTALLATION )
  27. INSTALL INSTRUMENT PANEL BOX  (See INSTALLATION )
  28. INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY  (See INSTALLATION )
  29. INSTALL INSTRUMENT PAD LOWER RH  (See INSTALLATION )
  30. INSTALL INSTRUMENT PAD LOWER LH  (See INSTALLATION )
  31. INSTALL REAR CONSOLE BOX ASSEMBLY  (See INSTALLATION )
  32. INSTALL CONSOLE BOX CARPET  (See INSTALLATION )
  33. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY  (See INSTALLATION )
  34. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY  (See INSTALLATION )
  35. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  36. INSTALL COWL SIDE TRIM BOARD RH  (See INSTALLATION )
  37. INSTALL COWL SIDE TRIM BOARD LH  (See INSTALLATION )
  38. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY RH  (See INSTALLATION )
  39. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH  (See INSTALLATION )
  40. INSTALL FRONT DOOR SCUFF PLATE RH  (See INSTALLATION )
  41. INSTALL FRONT DOOR SCUFF PLATE LH  (See INSTALLATION )
  42. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY  (See INSTALLATION )
  43. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  44. INSTALL FRONT PILLAR GARNISH RH  (See INSTALLATION )
  45. INSTALL FRONT PILLAR GARNISH LH  (See INSTALLATION )
  46. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH  (See INSTALLATION )
  47. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH  (See INSTALLATION )
  48. CONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY (See INSTALLATION  )
  49. CONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (See INSTALLATION  )
  50. CONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY (See INSTALLATION  )
  51. INSTALL AIR CONDITIONING PANEL ASSEMBLY (See INSTALLATION  )
  52. INSTALL STEREO OPENING COVER (w/o Radio Receiver)  (See INSTALLATION )
  53. INSTALL RADIO RECEIVER ASSEMBLY  (See INSTALLATION )
  54. INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER SUB-ASSEMBLY  (See INSTALLATION )
  55. INSTALL COMBINATION METER ASSEMBLY  (See INSTALLATION )
  56. INSTALL INSTRUMENT CLUSTER FINISH PANEL  (See INSTALLATION )
  57. INSTALL INSTRUMENT PANEL FINISH PANEL END RH  (See INSTALLATION )
  58. INSTALL INSTRUMENT PANEL FINISH PANEL END LH  (See INSTALLATION )
  59. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER  (See INSTALLATION )
  60. CONNECT HEATER WATER INLET 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 22: Identifying Hose Clip And Mark Angle For Heater Water Inlet Hose
      G04829661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. CONNECT HEATER WATER OUTLET HOSE 
    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.
  62. INSTALL LIQUID TUBE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the 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 the liquid tube.

      Compressor oil: ND-OIL8 or the equivalent 

    3. Install the O-ring onto the liquid tube.
    4. Connect the liquid tube to the unit.
      Fig 23: Identifying Hose Clip And Mark Angle For Heater Water Outlet Hose
      G04829662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. 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 the suction tube.

      Compressor oil: ND-OIL8 or the equivalent 

    3. Install the O-ring onto the suction tube.
    4. Insert the tube joints securely into the fitting holes and tighten the bolt.

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

  64. ADD ENGINE COOLANT (for 1NZ-FE)  (See REPLACEMENT )
  65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

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

  66. CHECK SRS WARNING LIGHT 

    DIAGNOSIS SYSTEM

    Fig 24: Locating Tube Joints Into Fitting Holes
    G04829663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. CHARGE REFRIGERANT (See REPLACEMENT  )
  68. WARM UP ENGINE (See REPLACEMENT  )
  69. CHECK FOR ENGINE COOLANT LEAK (for 1NZ-FE)  (See ON-VEHICLE INSPECTION )
  70. CHECK FOR REFRIGERANT LEAK (See REPLACEMENT  )
  71. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
  72. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT  (See INSTALLATION )
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