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Home >> Toyota >> 2018 >> Prius Two Eco >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System - Service Information (1 Of 2) >> Air Conditioning Unit >> Installation [11/2015 - 11/2017] >> Procedure

Installation [11/2015 - 11/2017]: Procedure

  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY 
    NOTE:
    • Be sure to support the air conditioner unit assembly when installing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
    • When installing the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. Engage the 2 guides and claw to connect the ID code box (immobiliser code ECU) as shown in the illustration.
      GTY597066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.
      GTY543049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    3. Connect each connector.
    4. Install the 4 bolts (A).

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    5. Connect the parking brake pedal assembly with the bolt (B).

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

    6. Temporarily install the nut.
    7. Install the 2 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    8. Connect the drain cooler hose.
    9. Engage each clamp.
    10. Connect the relay block assembly with the bolt.

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

    11. Connect the 3 earth wires with the 3 bolts.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    12. Connect each connector.
  3. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Engage the 6 claws to install the lower defroster nozzle assembly.
  4. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 3

  5. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 
    1. Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

      Bolt 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Nut 

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

    2. Engage the clamp and 2 claws to connect the DLC3 connector.
  6. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.

      Bolt 

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

      Nut 

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Temporarily install the screw.

      HINT: 

      Do not fully tighten the screw.

    3. Engage each clamp.
    4. GTY553233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front floor mat to its original position as shown in the illustration.

  7. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

      Bolt 

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

      Nut 

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Temporarily install the screw.

      HINT: 

      Do not fully tighten the screw.

    3. Connect the earth wire with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    4. Engage each clamp.
    5. GTY553250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front floor mat to its original position as shown in the illustration.

  8. INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.
      Fig 1: Air Conditioner Unit Assembly Tightening Sequence
      GTY610465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
      Nut - -

      Bolt 

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

      Nut 

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

      NOTE:

      Tighten the bolts, screws and nut in the order shown in the illustration.

  9. INSTALL NO. 3 DASH PANEL INSULATOR PAD 
    1. Install the No. 3 dash panel insulator pad with 2 new clips as shown in the illustration.
      GTY755484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 4 claws to install the rear No. 1 air duct.
  11. INSTALL REAR NO. 4 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 4 air duct.
  12. INSTALL REAR NO. 5 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 5 air duct as shown in the illustration.
      GTY602342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. GTY553251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front floor carpet assembly to its original position as shown in the illustration.

    3. Engage the 2 guides.
    4. Install the 2 front floor carpet clips.
  13. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 2 air duct.
  14. INSTALL REAR NO. 3 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 3 air duct as shown in the illustration.
      GTY548876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front floor carpet assembly to its original position as shown in the illustration.
      GTY553262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 2 guides.
    4. Install the 2 front floor carpet clips.
  15. INSTALL FRONT FLOOR CAUTION PLATE COVER 
    1. Engage the guide and claw to install the front floor caution plate cover as shown in the illustration.
      GTY541054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction

      HINT: 

      When replacing a type A front floor carpet assembly with a type B front floor carpet assembly, it is not necessary to install the front floor caution plate cover.

      GTY1025854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
  16. INSTALL FRONT NO. 2 CONSOLE BOX INSERT 
    1. Engage the guide as shown in the illustration.
      GTY586405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the claw and clip to install the front No. 2 console box insert as shown in the illustration.
      GTY595372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  17. INSTALL FRONT NO. 1 CONSOLE BOX INSERT 
    1. Engage the guide as shown in the illustration.
      GTY597761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the claw and clip to install the front No. 1 console box insert as shown in the illustration.
      GTY562824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  18. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.
  19. INSTALL SHIFT LOCK CONTROL UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  20. INSTALL ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 2

  21. INSTALL BACK-UP BATTERY WITH BRACKET (w/ Manual (SOS) Switch) 

    Refer to PROCEDURE - Step 4

  22. INSTALL CLEARANCE WARNING ECU ASSEMBLY (w/ TOYOTA Parking Assist-sensor System) 

    Refer to PROCEDURE - Step 1

  23. INSTALL NO. 2 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System) 

    Refer to PROCEDURE - Step 2

  24. INSTALL NO. 1 CLEARANCE WARNING BUZZER (w/ TOYOTA Parking Assist-sensor System) 

    Refer to PROCEDURE - Step 1

  25. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor) 

    Refer to PROCEDURE - Step 1

  26. INSTALL DRIVING SUPPORT ECU ASSEMBLY (w/ Toyota Safety Sense P) 

    Refer to PROCEDURE - Step 1

  27. INSTALL SKID CONTROL BUZZER (w/ Toyota Safety Sense P) 

    Refer to PROCEDURE - Step 1

  28. INSTALL STEERING COLUMN ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  29. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY 

    Refer to INSTALLATION [11/2015 - 11/2017]

  30. INSTALL FRONT SEAT ASSEMBLY LH 

    for Manual seat:

    Refer to INSTALLATION [11/2015 - ]

    for Power seat:

    Refer to INSTALLATION [11/2015 - ]

  31. INSTALL FRONT SEAT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to INSTALLATION [11/2015 - ]

  32. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the vinyl tape from the air conditioner tube and accessory assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioner tube and accessory assembly.

      Compressor Oil

      ND-OIL 11 or equivalent

    3. Install the O-ring to the air conditioner tube and accessory assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the air conditioner tube and accessory assembly.
  33. CONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction pipe sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor Oil

      ND-OIL 11 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Connect the suction pipe sub-assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY562718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the hose joint into the fitting hole securely and install the bolt.

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

  34. CONNECT INLET HEATER WATER HOSE A 
    1. w/o Exhaust Heat Recirculation System:
      1. Connect the inlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.
        GTY584361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a View A
        *b Marking (Brown)
        *c Clip Installation Angle (60°)
        NOTE:

        Do not apply excessive force to the inlet heater water hose A.

    2. w/ Exhaust Heat Recirculation System:
      1. Connect the inlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.
        GTY599133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a View A
        *b Marking (Blue)
        *c Clip Installation Angle (60°)
        NOTE:

        Do not apply excessive force to the inlet heater water hose A.

  35. CONNECT OUTLET HEATER WATER HOSE A (w/o Exhaust Heat Recirculation System) 
    1. Connect the outlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.
      GTY606336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Red)
      *c Clip Installation Angle (60°)
      NOTE:

      Do not apply excessive force to the outlet heater water hose A.

  36. CONNECT WATER PIPE AND HOSE SUB-ASSEMBLY A (w/ Exhaust Heat Recirculation System) 
    1. Connect the water pipe and hose sub-assembly A with the marking facing up and engage the clip within the area shown in the illustration.
      GTY558225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Green)
      *c Clip Installation Angle (60°)
      NOTE:

      Do not apply excessive force to the water pipe and hose sub-assembly A.

  37. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  38. INSTALL COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 15

  39. INSTALL WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 16

  40. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 17

  41. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  42. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 3 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 3 [08/2016 - 07/2020]

  43. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 1 [08/2016 - 07/2020]

  44. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  45. WARM UP COMPRESSOR 

    See step  3

  46. INSPECT FOR REFRIGERANT LEAK 

    See step  4

  47. INITIALIZE SERVO MOTOR 

    Refer to INITIALIZATION [11/2015 - ]

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