Air Conditioning Unit Installation

Attach the 2 claws to install the No. 3 air duct.

Temporarily install the air conditioning unit assembly with the bolt and nut.

NOTICE:

1. 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.
   
2. When installing the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
   

Install the No. 1 cooler unit drain hose.

Install the instrument panel reinforcement with the 8 bolts.

Torque:

for bolt A:

20 N*m{204 kgf*cm, 15 ft.*lbf}

for bolt B:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Temporarily install the 3 bolts.

Connect the connectors.

Attach the 12 clamps.

Install the grommet to the vehicle body.

Connect the ground wires to the instrument panel reinforcement with the 2 bolts.

for Automatic Air Conditioning System:
Connect the 2 connectors and attach the clamp.

for Manual Air Conditioning System:
Connect the 2 connectors and attach the clamp.

Connect the connector and attach the 3 clamps.

for 1KD-FTV:
(HILUX_TGN26 RM0000013YY01EX.html)

for 2KD-FTV:
(HILUX_TGN26 RM0000043GZ00GX.html)

for 2TR-FE:
(HILUX_TGN26 RM000000VW002OX.html)

for 2TR-FBE:
(HILUX_TGN26 RM000000VW0028X.html)

Attach the 2 claws to install the air conditioning duct sub-assembly.

Tighten the 3 bolts in the order shown in the illustration.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Temporarily install the screw.

Tighten the bolt and nut in the order shown in the illustration.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the driver side junction block with the 2 nuts labeled A.

Connect the connectors.

Attach the 2 clamps.

Install the No. 1 instrument panel brace sub-assembly with the nut labeled B and bolt.

Torque:

for nut:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Tighten the screw.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Attach the 2 claws to install the No. 4 air duct.

Attach the 2 claws to install the No. 2 air duct.

Attach the 2 claws to install the No. 1 air duct.

Attach the 4 clips to install the defroster nozzle assembly.

Attach the 4 claws to install the No. 3 heater to register duct.

Install the clip.

Attach the 3 claws to install the No. 1 heater to register duct.

Install the clip.

Install the No. 2 heater to register duct with the 3 clips.

Connect the heater water outlet hose and attach the clip.

Connect the heater water inlet hose and attach the clip.

Remove the vinyl tape attached to the air conditioning tube and accessory assembly.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the air conditioning tube and accessory assembly.

Connect the air conditioning tube and accessory assembly.

Remove the vinyl tape attached to the suction hose sub-assembly.

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

Install the O-ring to the suction hose sub-assembly.

Connect the suction hose sub-assembly and attach the piping clamp.

HINT:

After the connection, check that the claw of the piping clamp is attached.

Install the bolt.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

for 1KD-FTV:
(HILUX_TGN26 RM000002SLF00QX_01_0002.html)

for 2KD-FTV:
(HILUX_TGN26 RM000002SLF00RX_01_0002.html)

for 2TR-FE:
(HILUX_TGN26 RM0000017H500NX_01_0002.html)

for 2TR-FBE:
(HILUX_TGN26 RM000003PS1007X_02_0002.html)

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

SST

09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

Standard:

450 +/-30 g (15.9 +/-1.1 oz)

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. The system may need to be charged with approximately 100 g (3.53 oz) of refrigerant after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
   

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

SST

09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

Standard:

450 +/-30 g (15.9 +/-1.1 oz)

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. The system may need to be charged with approximately 100 g (3.53 oz) of refrigerant after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
   

for 1KD-FTV:
(HILUX_TGN26 RM000002SLF00QX_01_0006.html)

for 2KD-FTV:
(HILUX_TGN26 RM000002SLF00RX_01_0006.html)

for 2TR-FE:
(HILUX_TGN26 RM0000017H500NX_01_0013.html)

for 2TR-FBE:
(HILUX_TGN26 RM000003PS1007X_02_0006.html)

After recharging the refrigerant, check for refrigerant gas leakage using a halogen leak detector.

1. Perform the operation observing the following instructions:
   

   1. Stop the engine.
      
   2. Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
      
   3. Repeat the test 2 or 3 times.
      
   4. Make sure that some refrigerant remains in the refrigeration system.
      

      HINT:

      When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm², 57 to 85 psi).





2. Using a halogen leak detector, check the refrigerant line for leakage.
   

3. If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.
   

4. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.
   

   Text in Illustration

   *1	Halogen Leak Detector
   *a	Check for Leakage