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Home >> Toyota >> 2021 >> Mirai Limited >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Air Conditioning System - Service Information (2 Of 3) >> Air Conditioning Unit >> Installation [11/2020 - 12/2022] >> Procedure

Installation [11/2020 - 12/2022]: Procedure

  1. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY 
    1. Fig 1: Air Conditioner Unit Assembly Tightening Sequence
      GTY992451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily tighten the air conditioning unit assembly with the 3 bolts in the order shown in the illustration.
  2. INSTALL ID CODE BOX (IMMOBILIZER CODE ECU) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1 [11/2020 - 11/2021] , or refer to PROCEDURE - Step 1 [11/2021 - 12/2022]
  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
    • Do not hold the air conditioning harness assembly. Otherwise, static electricity from the technician may damage the air conditioning harness assembly.
    • Do not hold the heater core or pipe of the heater radiator unit sub-assembly. Otherwise, the pipe may detach, the clamp may be damaged, or the crimped areas of the heater core and pipe of the heater radiator unit sub-assembly may be damaged, causing coolant to leak.
    • Do not hold the air conditioning radiator damper servo sub-assembly, blower damper servo sub-assembly or link. Otherwise, the servo motor may become misaligned, causing abnormal operation noise, temperature control defects, or air leaks due to sealing defects in the doors.
    • Do not hold the door. Doing so may cause air leaks due to closing defects resulting from excessive opening/closing. Also, keep the door free from oil and grease.
    1. GTY992554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install to Guide by Inserting to the End - -
      1. Connect the connector and attach the clamp.
      2. Install the instrument panel reinforcement assembly with air conditioning unit assembly to the guide as shown in the illustration.
        NOTE:
        • Be careful not to damage the internal components of the instrument panel reinforcement assembly and air conditioning unit assembly on the glass etc. Only perform installation after first taking the appropriate actions.
        • Make sure that both parts are securely installed to the guide.
    2. GTY992266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A) *b Bolt (B)
      *c Bolt (C) *d Bolt (D)
      Bolt Nut
      1. Temporarily install the 4 bolts (A).
      2. Temporarily install the bolt (C).
      3. Temporarily install the bolt (B).
      4. Using a universal socket wrench 12 mm, temporarily install the 2 bolts (D).
      5. Temporarily install the nut.
      6. Tighten the 4 bolts (A).

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

      7. Tighten the bolt (C).

        Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

      8. Tighten the bolt (B).

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

      9. Using a universal socket wrench 12 mm, tighten the 2 bolts (D).

        Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

  4. INSTALL COOLER UNIT DRAIN HOSE GROMMET 
    1. GTY992441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lip - -
      1. Press the entire upper surface of the rib on a new cooler unit drain hose grommet, and fit the entire circumference of the lip to the hole.
        NOTE:
        • If the drain cooler hose is disconnected from the cooler unit drain hose grommet, make sure to replace the cooler unit drain hose grommet with a new one. Failure to do so may lead to water ingress.
        • Make sure that the entire lip of the cooler unit drain hose grommet is securely engaged to the vehicle body.
  5. INSTALL NO. 4 COOLER UNIT DRAIN HOSE 
  6. INSTALL NO. 3 COOLER UNIT DRAIN HOSE 
  7. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. GTY991975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      Screw - -
      1. Install the No. 2 instrument panel brace sub-assembly with the 2 nuts and bolt.
        NOTE:

        Check for the No. 2 instrument panel brace sub-assembly and air conditioner harness assembly do not interfere.

        Bolt 

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

        Nut 

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

      2. Temporarily install the screw.
      3. Attach the clamp.
  8. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. GTY992817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      Screw - -
      1. Install the No. 1 instrument panel brace sub-assembly with the 2 nuts and bolt.

        Bolt 

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

        Nut 

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

      2. Temporarily install the screw.
      3. Attach the clamp.
  9. TIGHTEN AIR CONDITIONER UNIT ASSEMBLY 
    1. Fig 2: Air Conditioner Unit Assembly Tightening Sequence
      GTY992944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      Screw - -
      1. Tighten the 3 bolts, 2 screws and nut in the order shown in the illustration.

        Bolt 

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

        Nut 

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

  10. CONNECT INSTRUMENT PANEL WIRE 

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

  11. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY WITH HEATER BRACKET 
  12. INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 4
  13. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY 

    Bolt 

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

    Nut 

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

  14. INSTALL NO. 1 HEATER TO REGISTER DUCT 
  15. INSTALL NO. 3 HEATER TO REGISTER DUCT 
  16. INSTALL NO. 1 INSTRUMENT PANEL SHIFT MOUNTING BRACKET 
  17. INSTALL NO. 4 HEATER TO REGISTER DUCT 
  18. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BRACKET 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 3 [11/2020 - 11/2021] , or refer to PROCEDURE - Step 3 [11/2021 - 12/2022]
  19. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY 
  20. INSTALL NAVIGATION ECU ASSEMBLY WITH BRACKET 
  21. INSTALL NO. 2 SIDE DEFROSTER NOZZLE DUCT 
  22. INSTALL NO. 5 HEATER TO REGISTER DUCT 
  23. INSTALL STEREO COMPONENT EQUALIZER ASSEMBLY 
  24. INSTALL WIRING HARNESS CLAMP BRACKET 

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

  25. INSTALL NO. 1 SEMICONDUCTOR POWER INTEGRATION ECU 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  26. INSTALL SHIFT CONTROL ECU 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 3
  27. CONNECT FRONT COMPARTMENT WIRE MAIN 
  28. INSTALL PASSENGER SIDE JUNCTION BLOCK ASSEMBLY 

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

  29. INSTALL EV CONTROL ECU WITH EV CONTROL ECU BRACKET 
  30. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY 
  31. INSTALL FRONT FLOOR MAT LH 
  32. INSTALL REAR NO. 3 AIR DUCT 
  33. INSTALL REAR NO. 4 AIR DUCT 
  34. INSTALL FRONT FLOOR MAT RH 
  35. INSTALL REAR NO. 1 AIR DUCT 
  36. INSTALL REAR NO. 2 AIR DUCT 
  37. INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY 
  38. INSTALL NO. 2 FLOOR CARPET HOOK 
  39. INSTALL REAR NO. 5 AIR DUCT 
  40. INSTALL AIR DUCT PLUG 
  41. INSTALL ACCELERATOR PEDAL ASSEMBLY 
  42. INSTALL ACCELERATOR PEDAL PAD 
  43. INSTALL LOWER CENTER PILLAR GARNISH LH 
  44. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  45. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  46. INSTALL REAR DOOR SCUFF PLATE INSIDE LH 
  47. INSTALL LOWER CENTER PILLAR GARNISH RH 
  48. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH 
    1. Use the same procedure described for the LH side.
  49. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 
    1. Use the same procedure described for the LH side.
  50. INSTALL REAR DOOR SCUFF PLATE INSIDE RH 
  51. INSTALL STEERING COLUMN ASSEMBLY 
  52. INSTALL METER MIRROR SUB-ASSEMBLY (w/ Headup Display) 

    Refer to INSTALLATION [11/2020 - 11/2021] , or refer to INSTALLATION [11/2021 - 12/2022]

  53. INSTALL INSTRUMENT PANEL SAFETY PAD 

    Refer to INSTALLATION [11/2020 - 12/2022]

  54. INSTALL FRONT SEAT ASSEMBLY LH 

    Refer to INSTALLATION [11/2020 - 12/2022]

  55. INSTALL FRONT SEAT ASSEMBLY RH 
    1. Use the same procedure described for the LH side.
  56. INSTALL GROMMET 
  57. CONNECT WATER HOSE SUB-ASSEMBLY C 
    1. GTY993136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Water Hose Sub-assembly C *2 Hose Clip
      *a View A *b Marking (Green)
      *c Hose Clip Installation Angle (30 to 60° From Above the Vehicle) *d Hose Clip Installation Range (3 to 7 mm (0.119 to 0.276 in.))
      *e Stopper - -
      1. Connect the water hose sub-assembly C with its marking facing upward and install the hose clip within the range shown in the illustration.
        NOTE:

        Do not apply excessive force to the water hose sub-assembly C.

  58. CONNECT WATER HOSE SUB-ASSEMBLY E 
    1. GTY992218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Water Hose Sub-assembly E *2 Hose Clip
      *a View A *b Marking (Blue)
      *c Hose Clip Installation Angle (15° From Above the Vehicle) *d Hose Clip Installation Range (3 to 7 mm (0.119 to 0.276 in.))
      *e Stopper - -
      1. Connect the water hose sub-assembly E with its marking facing upward and install the hose clip within the range shown in the illustration.
        NOTE:

        Do not apply excessive force to the water hose sub-assembly E.

  59. INSTALL COOLER PIPE GROMMET 
  60. CONNECT NO. 1 LIQUID TUBE 
    1. GTY992730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 liquid tube.

        Compressor Oil

        ND-OIL 11 or equivalent

      2. Install the O-ring to the No. 1 liquid tube.
        NOTE:

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

      3. Connect the No. 1 liquid tube.
  61. CONNECT SUCTION HOSE SUB-ASSEMBLY A 
    1. GTY992471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
      1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly A.

        Compressor Oil

        ND-OIL 11 or equivalent

      2. Install the O-ring to the suction hose sub-assembly A.
        NOTE:

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

      3. Rotate the 1-point tightening plate as shown in the illustration.
      4. Install the bolt.

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

  62. CONNECT FC CONVERTER POWER OUTLET CABLE (INVERTER WITH CONVERTER ASSEMBLY) 
  63. CONNECT FC AIR COMPRESSOR MOTOR CABLE ASSEMBLY 
  64. CONNECT FLOOR UNDER WIRE 
  65. CONNECT NO. 1 BATTERY PACK WIRE 
  66. INSTALL HOLE PLUG 
  67. INSTALL COWL VENTILATOR SPLASH SHIELD LH 
  68. INSTALL FRONT WIPER MOTOR AND LINK 

    Refer to INSTALLATION [11/2020 - ]

  69. ADD COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed)) 

    Refer to PROCEDURE - Step 7

  70. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 5

  71. INSPECT FOR COOLANT (TOYOTA GENUINE FC STACK COOLANT (Pre-mixed)) LEAK 

    Refer to PROCEDURE - Step 2

  72. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 6

  73. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 7

  74. INSTALL FRONT COMPARTMENT UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 165

  75. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR 

    Refer to PROCEDURE - Step 164

  76. INSTALL FRONT COMPARTMENT UNDER COVER 
  77. INSTALL LOWER RADIATOR AIR DEFLECTOR 
  78. INSTALL UPPER RADIATOR SUPPORT SEAL 
  79. INSTALL RADIATOR COVER PLATE 
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