Air Conditioning Unit (For Sedan) Installation

Install the air conditioning unit with the 3 screws.

Install the air conditioning amplifier with the screw.

Provisionally tighten the air conditioning unit with the 3 screws.

Install the instrument panel reinforcement and the air conditioning unit with the 9 bolts.

Install the 3 screws, 3 bolts and the nut in the sequence shown in the illustration.

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}for screw

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

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

Install the wire harness with the clamps and connect the connectors.

Engage the clamps.

Install the ground wire with the bolt.

Torque:

3.2 N*m{33 kgf*cm, 28 in.*lbf}

Install the ground wire with the bolt. (for Cold area specification vehicles)

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Install the drain hose into the position shown in the illustration.

NOTICE:

1. Install the drain hose with its UP mark facing upward, within the 60 degree range shown in the illustration.
   
2. Install the drain hose without twisting it.
   

Connect the connectors and install the wire harness.

Install the connector holder with the bolt.

Torque:

3.2 N*m{33 kgf*cm, 28 in.*lbf}

Install the main body ECU with the 2 bolts.

Torque:

3.2 N*m{33 kgf*cm, 28 in.*lbf}

Connect the 5 connectors and the 3 clamps.

Install the instrument panel brace with the bolt, screw and nut.

Torque:

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

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

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

Engage the clamp.

Engage the 4 claws and install the air duct.

Engage the 2 claws and install the air duct.

Engage the 4 claws and install the air duct.

Engage the 5 claws and install the defroster nozzle.

Connect the 3 clamps and connector and install the wire harness.

Engage the 3 claws and install the heater to register duct.

Install the steering column assembly onto the instrument panel reinforcement assembly with the bolt and 2 nuts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Connect all the connectors and clamp the wire harnesses onto the steering column assembly bracket.

Install the pedal support with the bolt and 4 nuts.

Torque:

Bolt:

24 N*m{241 kgf*cm, 17 ft.*lbf}

Nut:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Apply lithium soap base glycol grease to the push rod pin.

Install the push rod clevis with the push rod pin and clip.

Install the brake pedal return spring.

Apply MP grease No. 2 to the brake master cylinder push rod clevis pin and installation surfaces.

Install the 2 brake pedal bushes, and install the brake pedal with the nut and brake pedal shaft.

Torque:

37 N*m{375 kgf*cm, 27 ft.*lbf}

Apply lithium soap base glycol grease to the brake master cylinder push rod clevis pin and installation surfaces.

Connect the brake master cylinder push rod clevis to the brake pedal with the brake master cylinder push rod clevis pin, install the clip onto the brake master cylinder push rod clevis pin, and then install the brake pedal return spring.

Align the matchmarks and install the sliding yoke onto the power steering assembly with bolt B.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Tighten bolt A.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Install the column hole cover plate with the 2 clips.

Install the floor carpet.

Align the 2 claws and install the reinforcement instrument panel sub with the 2 bolts.

Connect the 2 steering column assembly connectors to the power steering ECU.

Install the power steering motor harness and torque sensor wire harness clamps onto the side of the power steering ECU.

Tilt the steering column assembly up and down to make sure that the power steering motor harness and torque sensor wire harness do not interfere with any components.

Install the combination switch assembly onto the steering column assembly with the clamp.

Connect all the connectors to the turn signal switch with spiral cable.

Engage the claw to install the steering column upper cover.

Engage the 2 claws to install the steering column lower cover.

Install the 3 screws.

Align the matchmarks and install the steering wheel assembly onto the steering column assembly.

Install the nut.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Connect all connectors to the spiral cable.

Confirm that the ignition switch is turned to OFF.

Confirm that the negative battery terminal is detached.

CAUTION:

Do not begin the operation for at least 90 seconds after the negative battery terminal is detached.

Connect the horn terminal.

Connect the airbag connector.

NOTICE:

1. Match the color of the airbag connector with that of the steering pad assembly, and install the airbag connector.
   
2. Securely lock the locking button.
   

Install the steering pad.

Using "Torx" socked wrench T30, tighten the 2 bolts.

Torque:

8.8 N*m{90 kgf*cm, 78 in.*lbf}

NOTICE:

Tighten the 2 bolts while holding the steering pad to prevent it moving upward.

Using a nipper, cut off both ends of the runner portion shown in the illustration (When installing a new one).

Install the lower instrument panel with the 6 <D> bolts, 2 <E> bolts, screw <G> and screw <H>.

NOTICE:

Do not excessively tighten the <D> bolts, as this may damage the area not being tightened.

Connect the clamps and connectors.

Engage the 2 claws and connect the DLC3 connector.

Engage the 3 claws to connect the control lever.

Connect the 5 antenna cord clamps.

Insert the stopper of the instrument panel box from the cutout of the instrument panel lower.

Engage the 2 hinges with the instrument panel open.

Close the instrument panel box.

Install the 2 <A> screws.

Engage the 7 claws and install the instrument panel lower finish panel.

Engage the claw and 3 clips and install the instrument pad lower.

Install screw <I>.

Engage the claw and 3 clips and install the instrument pad lower.

Install screw <I>.

Engage the 4 claws and install the rear console box.

Install the 2 bolts and 2 screws.

Connect the clamp.

Install the console box carpet.

Connect the connector.

Engage the 3 clips and 3 claws and install the console upper rear panel.

Engage the 5 clips and the claw and install the upper console panel.

Install the shift lever knob.

Engage the stud bolt and the claw and install the cowl side trim board.

Engage the 4 claws and install the instrument panel under cover.

Engage the 3 claws and install the instrument panel under cover.

Tighten the 2 screws.

Engage the 11 claws and install the front door scuff plate.

Using a nipper, cut off both ends of the runner portion shown in the illustration (When installing a new one).

Engage the 5 claws at the front side of the instrument panel.

Engage the 7 clips at the rear side of the instrument panel.

Install the upper instrument panel with the 2 <C> bolts and the 2 <B> screws.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf} for bolt <C>

Connect the passenger airbag connector and clamp.

Engage the claws of the hinge portions by pushing the glove compartment door in the horizontal direction to install the glove compartment door assembly.

NOTICE:

Engage the claw by pushing it in the horizontal direction, otherwise, installation failure caused by excessive play around the hinge portion will result.

Slightly flex the upper portion of the glove compartment door assembly to engage the stopper.

Install the 2 glove compartment door stoppers onto the glove compartment door.

w/ Curtain Shield Airbag:

1. Remove the piece of cloth or nylon.
   

Install the 3 clamps.

Connect the antenna connector.

w/ Curtain Shield Airbag:

1. Install 2 new special clips and the clip onto the front pillar garnish.
   

2. Engage the 2 clips and the 2 claws and install the front pillar garnish.
   

w/o Curtain Shield Airbag:

1. Engage the 2 clips and the 2 claws and install the front pillar garnish.
   

w/ Curtain Shield Airbag:

1. Remove the piece of cloth or nylon.
   

Install the 4 clamps.

w/ Curtain Shield Airbag:

1. Install 2 new special clips and the clip onto the front pillar garnish.
   

2. Engage the 2 clips and the 2 claws and install the front pillar garnish.
   

w/o Curtain Shield Airbag:

1. Engage the 2 clips and the 2 claws and install the front pillar garnish.
   

Align the location mark with the paint mark first, and install the front door opening trim weatherstrip, as shown in the illustration.

Paint mark:

Area	Color
RH side	Blue
LH side	Pink

Engage the 2 claws and connect the air inlet damper control cable.

Engage the 2 claws and connect the defroster damper control cable.

Engage the 2 claws and connect the air mix control cable clamp.

Connect the air mix damper control cable to the clamp.

Connect the 3 connectors and the 4 clamps.

Engage the 4 clips and 2 claws and install the air conditioning panel.

Install the stereo opening cover with the 4 screws.

for Integrated with Panel:

1. Connect the plug.
   

2. Connect the 3 radio connectors.
   





3. Align the 2 bosses of the instrument panel with the hole in the radio bracket.
   

4. Engage the 4 clips and 4 claws and install the radio receiver.
   





5. Tighten the 4 bolts.
   

6. Connect the hazard warning signal switch connector.
   

except Integrated with Panel:

1. Connect the plug.
   

2. Connect the 2 radio connectors.
   





3. Align the 2 bosses of the instrument panel with the hole in the radio bracket.
   

4. Install the radio receiver with the 4 bolts.
   

Engage the 2 claws and 4 clips and install the instrument cluster finish panel center.

Install the combination meter assembly with the 2 screws.

NOTICE:

Install the meter by inserting the ribbed portions of the meter between the instrument panel and meter cluster.

Connect the 2 connectors.

Fit the 2 claws of the instrument cluster finish panel into the upper instrument cluster finish panel center.

Engage the 5 claws and 5 clips and install the instrument cluster finish panel.

Engage the 6 claws and 3 clips and install the instrument panel finish panel end RH.

Engage the 6 claws and 3 clips and install the instrument panel finish panel end LH.

Engage the 2 claws and 2 clips and install the instrument panel finish panel lower center.

Install the heater water inlet hose onto the heater unit.

NOTICE:

Perform the installation with the hose clip and mark at the correct angle as shown in the illustration.

Install the heater water outlet hose onto the heater unit.

NOTICE:

Perform the installation with the hose clip and mark at the correct angle as shown in the illustration.

Remove the vinyl tape from the liquid tube and the connecting portion of the unit.

Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the liquid tube.

Compressor oil:

ND-OIL8 or the equivalent

Install the O-ring onto the liquid tube.

Connect the liquid tube to the unit.

Remove the vinyl tape from the suction tube and the connecting part of the unit.

Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the suction tube.

Compressor oil:

ND-OIL8 or the equivalent

Install the O-ring onto the suction tube.

Insert the tube joints securely into the fitting holes and tighten the bolt.

Torque:

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

Tighten all the plugs.

Pour engine coolant into the radiator assembly until it overflows.

Capacity:

M/T 4.8 liters (5.1 USqts, 4.5 lmp. qts)

A/T 4.7 liters (5.0 USqts, 4.4 lmp. qts)

NOTICE:

Do not substitute water for engine coolant.

HINT:

1. Use of improper engine coolant may damage the engine coolant system.
   
2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   

Check the engine coolant level inside the radiator assembly by squeezing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

Install the radiator cap sub-assembly securely.

Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when when the coolant starts to flow inside the hose.

2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.
   

3. Press the No. 2 radiator hose and No. 3 radiator hose several times by hand to bleed air.
   

   NOTICE:

   When pressing the radiator houses

   1. Wear protective glove.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away form the radiator fan.
      

Stop the engine and wait until the coolant cools down.

If the engine coolant level is below the full level, perform steps (b) through (g) again and repeat the operation until the engine coolant level stays at the full level.

Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add engine coolant.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

SST

09985-20010(09985-02010,09985-02050,09985-02060,09985-02070,09985-02080,09985-02090,09985-02110,09985-02130,09985-02140,09985-02150)

Standard:

330 to 390g (11.64 to 13.76oz.)

NOTICE:

Do not start the engine before charging it with refrigerant as the cooler compressor doesn't work properly without sufficient refrigerant. This could cause the compressor to overheat.

HINT:

1. The relationship between refrigerant charge amount and pressure is as follows.
   
   
   
   
   
   
2. High Charge Range:
   If refrigerant is overcharged, pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.
   
3. Low Charge Range:
   Shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens compressor life. Operation with insufficient coolant raises refrigerant temperature and causes heat deterioration of rubber seals and hoses. Cracking and thus refrigerant leakage may occur.
   

1. Install the caps onto the service valves on the refrigerant line.
   

Fill the radiator assembly with engine coolant, and attach a radiator cap tester.

Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.

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

Perform the operation as follows:

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.
   When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf*cm², 57 to 85 psi)
   

HINT:

It is impossible for the above pressure to be maintained if there is leakage.

Using the halogen leak detector, check the refrigerant line, especially the connection points, for leakage.

Bring the halogen leak detector close to the drain hose before performing the test.

HINT:

1. After the blower motor has stopped, leave the cooling unit for at least 15 minutes.
   
2. Place the halogen leak detector sensor under the drain hose.
   
3. When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to the volatile gases.
   

If a gas leak is not detected from the drain hose, remove the blower motor from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.