Installation [06/2020 - 10/2022]: Procedure
- INSTALL COOLER UNIT DRAIN HOSE GROMMET NOTE:
Perform this procedure only when removal/installation of the cooler unit drain hose grommet is necessary.
After removing the cooler unit drain hose grommet, replace it with a new one to prevent water from entering.
- Attach one side of the lip on a new cooler unit drain hose grommet (approximately 1/3 of the circumference) to the body hole (fit it to the hole).
*a Lip Penetrate Area - Press the entire upper surface of the rib on the cooler unit drain hose grommet, and fit the entire circumference of the lip to the hole.NOTE:
- If the lip on the cooler unit drain hose grommet is not completely fit to the hole, water or noise may enter the interior. When fitting the lip to the hole, make sure that there are no gaps between the lip and body.
- Do not allow any foreign matter to be trapped between the cooler unit drain hose grommet and installation area, as this may allow noise to enter.
- Removing the cooler unit drain hose grommet after it has been installed damages the lip due to burrs on the body punch hole (vehicle exterior). This may reduce contact between the edge of the lip and body and cause water to enter the interior. Therefore, do not reuse the cooler unit drain hose grommet.
- When installing the cooler unit drain hose grommet, do not leave the lip only partially fit to the hole (as in the previous step). This may reduce contact due to lip deformation and cause water to enter the interior. Once you have started to install the part, complete the installation without stopping.
Rib Upper Surface
- Attach one side of the lip on a new cooler unit drain hose grommet (approximately 1/3 of the circumference) to the body hole (fit it to the hole).
- INSTALL ID CODE BOX (IMMOBILIZER CODE ECU)
Refer to PROCEDURE - Step 1
- INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY
HINT:
Perform this procedure only when removal/installation of the No. 1 air duct sub-assembly is necessary.
- Install the No. 1 air duct sub-assembly with the 2 nuts in the order shown in the illustration.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
NOTE:- Make sure there are no cracks in the No. 1 air duct sub-assembly.
- Make sure no foreign matter, such as the dash panel insulator, is trapped between the cowl and seal packing.
- Make sure that the seal packing is securely attached to the cowl on the body. Look from the engine compartment and check that it does not drop down into the fresh air vent. (If foreign matter, such as the dash panel insulator, is trapped or if the seal packing is not securely attached, water or air from gaps may enter the interior.)
- Install the No. 1 air duct sub-assembly with the 2 nuts in the order shown in the illustration.
- INSTALL AIR CONDITIONING UNIT ASSEMBLY NOTE:
- Be sure to support the air conditioning unit assembly when installing it because 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.
- 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.
- Do not allow the air conditioning unit assembly to strike the airbag sensor assembly. Doing so may damage the heater case, causing water leaks.
- Temporarily set the air conditioning unit assembly nearby the position where it is to be installed.NOTE:
When carrying the air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts.
- 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.
- Temporarily install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
- CONNECT INSTRUMENT PANEL WIRE
- INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY NOTE:
- Be sure to support the air conditioning unit assembly when installing it because 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.
- Be careful not to damage the internal components of the instrument panel reinforcement assembly with air conditioning unit assembly on the glass etc. Only perform installation after first taking the appropriate actions.
- Install the instrument panel reinforcement assembly with air conditioning unit assembly to the guide as shown in the illustration.NOTE:
When carrying the instrument panel reinforcement assembly with air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts.
- 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.
NOTE:- Do not allow the heater radiator unit sub-assembly heater pipe or connector tube to strike the body.
- Make sure that both parts are securely installed to the guide.
Install in this Direction - - - Temporarily install the 4 bolts (C).
Bolt (B) Bolt (C) Nut - - - Temporarily install the bolt (B).
- Temporarily install the 3 bolts (A).
Bolt (A) - Temporarily install the nut.
- Tighten the 4 bolts (C).
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
- Tighten the 3 bolts (A).
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
- Tighten the bolt (B).
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
- INSTALL HEATER GROMMET
- Install the heater grommet.
*a Spool NOTE:- Push the heater grommet lip seal until it passes over the spools of the heater pipes as shown in the illustration.
- Make sure that the lip portion of the heater grommet does not sit on top of the spools of the heater pipes.
- Make sure that there is no gap between the heater grommet and dash panel.
- Securely fit the heater grommet onto the dash panel. Otherwise, water may enter from the engine room or cause increased noise, vibration or harshness.
- Install the heater grommet.
- CONNECT DRAIN COOLER HOSE NOTE:
If the cooler unit drain hose grommet was removed from the body, replace it with a new one.
- TEMPORARILY INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
- TEMPORARILY INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
- TIGHTEN INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY
- Tighten the 3 bolts, 2 nuts (A), and 2 screws in the order shown in the illustration.
Bolt
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
Nut (A)
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
HINT:
5 and 6 can be done in either order.
Fig 2: Instrument Panel Reinforcement Assembly With Air Conditioning Unit Assembly Tightening SequenceCourtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Bolt Nut (A) Nut (B) Screw - Tighten the nut (B).
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- Tighten the No. 2 instrument panel brace sub-assembly with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
- Tighten the No. 1 instrument panel brace sub-assembly with the bolt.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
- Tighten the 3 bolts, 2 nuts (A), and 2 screws in the order shown in the illustration.
- CONNECT ENGINE ROOM MAIN WIRE
- CONNECT INSTRUMENT PANEL WIRE
- INSTALL ECU INTEGRATION BOX RH
Refer to PROCEDURE - Step 2
- CONNECT INSTRUMENT PANEL WIRE
- Connect the lever connector.
Refer to PROCEDURE - Step 1
*A for Type A *B for Type B *a Clamp *b Guide Bolt Nut Connector Lever Connector - Attach the clamp.
- Connect the connector.
- Attach the guide.
- Connect the ground wire with the bolt.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
- Install the nut.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
- Attach the clamp.
*a Clamp *b Guide - Attach the guide.
- Connect the 2 ground wires with the 2 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
- Connect the 2 connectors.
*a Clamp *b Guide - Attach the guide and clamp.
- Connect the lever connector.
- INSTALL POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU
Refer to PROCEDURE - Step 2 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 2 [12/2021 - 10/2022]
- INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY
Refer to PROCEDURE - Step 3 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 3 [12/2021 - 10/2022]
- INSTALL NO. 2 HEATER TO REGISTER DUCT
- INSTALL NO. 1 CONSOLE BOX DUCT
- INSTALL REAR NO. 1 AIR DUCT
- INSTALL REAR NO. 2 AIR DUCT
- INSTALL REAR NO. 3 AIR DUCT
HINT:
Use the same procedure described for the rear No. 1 air duct.
- INSTALL REAR NO. 4 AIR DUCT
HINT:
Use the same procedure described for the rear No. 2 air duct.
- INSTALL NO. 3 DASH PANEL INSULATOR PAD
- INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY
- Install the front floor front carpet assembly to its original position as shown in the illustration.
Return to Original Position - - - Attach the guide.
- Install the clip.
- Install the front floor front carpet assembly to its original position as shown in the illustration.
Return to Original Position Fastener - Attach the guide.
- Attach the 3 fasteners.
- Install the clip.
- Install the front floor front carpet assembly to its original position as shown in the illustration.
- INSTALL FRONT FLOOR CAUTION PLATE COVER
- INSTALL ACCELERATOR PEDAL ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL ACCELERATOR PEDAL PAD
Refer to PROCEDURE - Step 2
- INSTALL LOWER CENTER PILLAR GARNISH LH
- Install the lower center pillar garnish LH.
Refer to PROCEDURE - Step 29 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 29 [12/2021 - ]
- Return the front door opening trim weatherstrip LH to its original position.
Refer to PROCEDURE - Step 1
- Return the rear door opening trim weatherstrip LH to its original position.
Refer to PROCEDURE - Step 1
- Install the lower center pillar garnish LH.
- INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH
Refer to PROCEDURE - Step 31 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 31 [12/2021 - ]
- INSTALL REAR DOOR SCUFF PLATE LH
Refer to PROCEDURE - Step 56 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 56 [12/2021 - ]
- INSTALL LOWER CENTER PILLAR GARNISH RH
HINT:
Use the same procedure described for the lower center pillar garnish LH.
- INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH
HINT:
Use the same procedure described for the front seat outer belt assembly LH.
- INSTALL REAR DOOR SCUFF PLATE RH
HINT:
Use the same procedure described for the rear door scuff plate LH.
- INSTALL OUTER LAP BELT ANCHOR COVER
Refer to PROCEDURE - Step 33 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 33 [12/2021 - ]
- INSTALL NAVIGATION ECU WITH BRACKET (w/ Navigation System)
Refer to PROCEDURE - Step 7
- INSTALL DCM (TELEPHONE TRANSCEIVER ASSEMBLY) WITH BRACKET (w/ DCM)
- w/ Navigation System:
Refer to PROCEDURE - Step 8
- w/o Navigation System:
Refer to PROCEDURE - Step 9
- w/ Navigation System:
- INSTALL STEERING COLUMN ASSEMBLY
Refer to INSTALLATION [06/2020 - 10/2022]
- INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY
Refer to INSTALLATION [06/2020 - 10/2022]
- INSTALL FRONT SEAT ASSEMBLY LH
Refer to INSTALLATION [06/2020 - 10/2022]
- INSTALL FRONT SEAT ASSEMBLY RH
- for Manual Seat:
Refer to INSTALLATION [06/2020 - 10/2022]
- for Power Seat:
Refer to INSTALLATION [06/2020 - 10/2022]
- for Manual Seat:
- CONNECT INLET HEATER WATER HOSE
- Connect the inlet heater water hose as shown in the illustration.NOTE:
- Do not apply excessive force to the inlet heater water hose.
- Make sure the inlet heater water hose is securely inserted to the stopper. However, If the end of the inlet heater water hose is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
- Connect the inlet heater water hose so that its marking faces the top of the vehicle.
*1 Hose Clip *2 Inlet Heater Water Hose *a View A *b Stopper *c Hose Clip Installation Angle (120°) *d Hose Marking Angle (75 to 105°) *e Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.)) - - - Make sure to install the hose clip within the range shown in the illustration.
- Connect the inlet heater water hose as shown in the illustration.
- CONNECT OUTLET HEATER WATER HOSE
- Connect the outlet heater water hose as shown in the illustration.NOTE:
- Do not apply excessive force to the outlet heater water hose.
- Make sure the outlet heater water hose is securely inserted to the stopper. However, If the end of the outlet heater water hose is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
- Connect the outlet heater water hose so that its marking faces the top of the vehicle.
*1 Hose Clip *2 Outlet Heater Water Hose *a View A *b Stopper *c Hose Clip Installation Angle (270°) *d Hose Marking Angle (75 to 105°) *e Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.)) - - - Make sure to install the hose clip within the range shown in the illustration.NOTE:
Make sure that the hose clamps do not contact each other.
- Connect the outlet heater water hose as shown in the illustration.
- CONNECT NO. 5 DISCHARGE TUBE
- Remove the vinyl tape wrapped around the connection of the No. 5 discharge tube and the No. 5 discharge tube.
- Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning unit.
Compressor Oil
ND-OIL 11 or equivalent
NOTE:Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
- Install the O-ring to the No. 5 discharge tube.NOTE:
Keep the O-ring and O-ring fitting surface free from foreign matter.
- Connect the No. 5 discharge tube.NOTE:
- Do not apply excessive force to the No. 5 discharge tube.
- Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
- CONNECT NO. 1 SUCTION TUBE
- Remove the vinyl tape wrapped around the connection of the No. 1 suction tube and No. 1 suction tube.
- Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning unit.
Compressor Oil
ND-OIL 11 or equivalent
NOTE:Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
- Install the O-ring to the No. 1 suction tube.NOTE:
Keep the O-ring and O-ring fitting surface free of foreign matter.
- Connect the No. 1 suction tube.NOTE:
- Do not apply excessive force to the No. 1 suction tube.
- Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
- Rotate the 1-point tightening plate as shown in the illustration.
Rotate in this Direction - Insert the tube joint into the fitting hole securely and install the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- INSTALL HOLE PLUG
- INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY
- INSTALL COWL VENTILATOR SPLASH SHIELD
- INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Refer to INSTALLATION [06/2020 - ]
- CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
See step 2
- ADD ENGINE COOLANT (for Engine)
Refer to PROCEDURE - Step 2
- INSPECT FOR COOLANT LEAK (for Engine)
Refer to PROCEDURE - Step 1
- WARM UP COMPRESSOR
See step 3
- INSPECT FOR REFRIGERANT LEAK
See step 4
- INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL
Refer to WORK PROCEDURE [06/2020 - 10/2022]
HINT:
When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.
Refer to AUTOMATIC LEARNING CHART [06/2020 - 12/2021] , or refer to AUTOMATIC LEARNING CHART [12/2021 - ]