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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System (Service Information) (Except Hybrid) (1 Of 2) >> Front Air Conditioning Unit >> Installation [12/2013 - 11/2016] >> Procedure

Installation [12/2013 - 11/2016]: Procedure

  1. TEMPORARILY INSTALL AIR CONDITIONING UNIT ASSEMBLY 
    1. Engage the 2 claws.
    2. Temporarily install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT 
    NOTE:
    • Be sure to support the air conditioning unit assembly when installing it. Failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • When installing the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
    1. w/ Engine Immobilizer System:
      1. Engage the 2 guides and claw to connect the transponder key ECU assembly as shown in the illustration.
        GTY440402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 guides to temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.
      GTY454008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 6 bolts as shown in the illustration.
      GTY444274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Vehicle Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
      Bolt Nut

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

    4. Temporarily install the nut.
    5. Connect the drain cooler hose.
    6. Install the 2 hole plugs.
    7. Engage the claw to connect the drain cooler hose to the piping clamp.
    8. Install the 2 bolts.

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

    9. Install the 2 hole plugs.
    10. Engage each clamp.
    11. Connect each connector.
    12. Connect the 4 earth wires with the 4 bolts.

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

  3. INSTALL INSTRUMENT PANEL SAFETY PAD CAP 
    1. Install 4 new instrument panel safety pad caps.
      GTY443586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for LH Side
      *B for RH Side
  4. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 2 instrument panel brace sub-assembly with the bolt, screw and 2 nuts.

      Bolt 

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

      HINT: 

      Do not fully tighten the screw.

    2. Engage each clamp.
  5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 1 instrument panel brace sub-assembly with the 2 bolts, screw and 2 nuts.

      Bolt 

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

      HINT: 

      Do not fully tighten the screw.

    2. Connect the earth wire with the bolt.

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

    3. Engage each clamp.
  6. FULLY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY 
    1. Tighten the 3 bolts, 2 screws and nut.
      Fig 1: Tightening Sequence Of Air Conditioning Unit Assembly
      GTY454064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
      Nut - -

      Bolt 

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

      Nut 

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      NOTE:

      Tighten the bolts, screws and nut in the order shown in the illustration to install the air conditioning unit assembly.

  7. INSTALL SHIFT LEVER SUPPORT 
    1. Install the 2 nuts.
      Fig 2: Tightening Sequence Of Shift Lever Support
      GTY451629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      NOTE:

      Tighten the nuts in the order shown in the illustration.

    2. Install the shift lever support with the 4 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

    3. Engage each clamp.
    4. Connect each connector.
  8. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY 

    for U660E Automatic Transmission / Transaxle:

    Refer to INSTALLATION [12/2013 - 11/2016]

    for U660F Automatic Transmission / Transaxle:

    Refer to INSTALLATION [12/2013 - 11/2016]

    for U760E Automatic Transmission / Transaxle:

    Refer to INSTALLATION [12/2013 - ]

  9. INSTALL REAR NO. 3 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 3 air duct.
  10. INSTALL REAR NO. 4 AIR DUCT 
    1. Install the rear No. 4 air duct with the clip.
    2. Install the front floor carpet assembly to the original position as shown in the illustration.
      GTY444508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fastener
    3. Engage the fastener and 4 guides.
  11. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 2 claws to install the rear No. 1 air duct.
    2. Engage the clamp to connect the wire harness.
  12. INSTALL REAR NO. 2 AIR DUCT 
    1. Install the rear No. 2 air duct with the clip.
    2. Install the front floor carpet assembly to the original position as shown in the illustration.
      GTY443019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fastener
    3. Engage the 2 fasteners and 4 guides.
  13. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System) 
    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.
  14. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket with the nut.
    2. Engage the 3 clamps.
  15. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to PROCEDURE - Step 2

  16. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  17. INSTALL ECU INTEGRATION BOX RH (w/ ECU Integration Box RH) 

    Refer to PROCEDURE - Step 2

  18. INSTALL STEERING POST ASSEMBLY 

    Refer to INSTALLATION [12/2013 - ]

  19. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 

    Refer to INSTALLATION [12/2013 - ]

  20. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) 

    Refer to INSTALLATION [12/2013 - ]

  21. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) 

    Refer to INSTALLATION [12/2013 - ]

  22. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) 

    HINT: 

    Use the same procedure as for the LH side.

  23. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat) 

    HINT: 

    Use the same procedure as for the LH side.

  24. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose with the marking facing left and engage the clip within the area shown in the illustration.
      GTY429081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b for 2GR-FE:
      Marking (Blue)
      for 1AR-FE:
      Marking (Pink)
      *c Clip Installation Angle (60 to 120°)
      NOTE:

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

  25. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose with the marking facing left and engage the clip within the area shown in the illustration.
      GTY443616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b for 2GR-FE:
      Marking (Blue)
      for 1AR-FE:
      Marking (Pink)
      *c Clip Installation Angle (15 to 75°)
      NOTE:

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

  26. 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 8 or equivalent

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

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
    4. Connect the suction hose sub-assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY440436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the hose joint into the fitting hole securely and tighten the bolt.

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

  28. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2GR-FE) 

    Refer to PROCEDURE - Step 10 , or refer to PROCEDURE - Step 10

  29. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 2GR-FE) 

    Refer to INSTALLATION [12/2013 - ]

  30. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  31. INSTALL FRONT FENDER TO COWL SIDE SEAL LH 

    Refer to PROCEDURE - Step 5

  32. INSTALL FRONT FENDER TO COWL SIDE SEAL RH 

    Refer to PROCEDURE - Step 6

  33. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  34. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH 

    Refer to PROCEDURE - Step 8

  35. INSTALL FRONT WIPER ARM HEAD CAP 

    Refer to PROCEDURE - Step 9

  36. ADD ENGINE COOLANT (for 1AR-FE) 

    Refer to PROCEDURE - Step 2

  37. ADD ENGINE COOLANT (for 2GR-FE) 

    Refer to PROCEDURE - Step 3

  38. INSPECT FOR COOLANT LEAK (for 1AR-FE) 

    Refer to PROCEDURE - Step 1

  39. INSPECT FOR COOLANT LEAK (for 2GR-FE) 

    Refer to PROCEDURE - Step 1

  40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  41. WARM UP ENGINE 

    See step  3

  42. INSPECT FOR REFRIGERANT LEAK 

    See step  4

  43. INITIALIZE SERVO MOTOR (for Manual Air Conditioning System) 

    Refer to INITIALIZATION [12/2013 - ]

  44. INITIALIZE SERVO MOTOR (for Automatic Air Conditioning System) 

    Refer to INITIALIZATION [12/2013 - ]

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