INSTALLATION

PROCEDURE

1. INSTALL AIR CONDITIONING UNIT

(a) Install the air conditioning unit to the instrument panel reinforcement with the 3 screws.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

2. INSTALL INSTRUMENT PANEL REINFORCEMENT

(a) Install the instrument panel reinforcement with air conditioning unit to the vehicle.

(b) Install the 5 bolts as shown in the illustration.

Text in Illustration

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

(c) Install the 2 caps.

(d) Install the 3 caps.

(e) Install the 3 bolts and nut.

Torque:

19 N·m {189 kgf·cm, 14 ft·lbf}

for bolt A

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

for nut

3. INSTALL INSTRUMENT PANEL WIRE

(a) Engage the clamps to install the instrument panel wire.

(b) Install the ground wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(c) Connect the connectors.

4. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Install the No. 1 air duct sub-assembly with the 3 nuts.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the No. 2 instrument panel brace sub-assembly with the bolt, 2 nuts and screw.

(b) Install the ground wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(c) Engage the 5 clamps.

(d) Connect the connector.

6. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the No. 1 instrument panel brace sub-assembly with the 2 bolts, 2 nuts and screw.

(b) Connect the ground wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(c) Engage the 5 clamps.

(d) Connect the connector.

7. INSTALL TELEVISION BRACKET

(a) Install the television bracket with the 4 bolts.

Torque:

9 N·m {90 kgf·cm, 79 in·lbf}

8. INSTALL NO. 5 INSTRUMENT PANEL BRACKET

(a) Install the No. 5 instrument panel bracket with the 3 nuts.

(b) Connect the 3 connectors.

HINT:

If the vehicle is equipped with USB audio system, connect the connector.

9. INSTALL REAR NO. 2 AIR DUCT

(a) Engage the 2 claws to install the No. 2 air duct.

(b) Install the clip.

10. INSTALL REAR NO. 4 AIR DUCT

HINT:

Use the same procedure as for the No. 2 side.

11. INSTALL FRONT FLOOR CARPET ASSEMBLY

(See page )

12. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY LH

(a) Temporarily install the front door panel sub-assembly LH with the 4 bolts.

(b) Pass the front door wire through the opening in the body.

(c) Tighten the 4 bolts on the hinge side.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

(d) Apply adhesive to the threads of the bolt.

NOTICE:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

(e) Install the front door check with the bolt.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

13. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

14. CONNECT FRONT DOOR WIRE LH

(a) Connect the 3 connectors.

15. CONNECT FRONT DOOR WIRE RH

(a) Connect the 3 connectors.

16. INSTALL CENTER AIRBAG SENSOR ASSEMBLY

17. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

18. INSTALL ECU INTEGRATION BOX RH

19. INSTALL STEERING COLUMN ASSEMBLY

(See page )

20. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

(a) Engage the 3 claws to install the No. 3 air duct sub-assembly.

(b) Install the clip.

21. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY

(See page )

22. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

(a) Remove the vinyl tape from air conditioner tube and accessory and connecting portion of the unit.

(b) Sufficiently apply compressor oil to 2 new O-rings and connecting part of the air conditioner tube and accessory assembly.

Compressor oil:

ND-OIL8 or equivalent

(c) Install the 2 O-rings to the air conditioner tube and accessory assembly.

(d) Turn the hook connector in the direction indicated by the arrow in the illustration.

(e) Insert the pipe joints securely into the fitting holes and install the bolt.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

23. CONNECT HEATER WATER INLET HOSE A

(a) Install the heater water inlet hose A to the air conditioning unit with the clip. Text in Illustration *a View A *b UP Side *c 25 to 65 ° *d -20 to 20 ° *e White Paint Mark HINT: Perform the installation with the hose clip and mark at the correct angle.

24. CONNECT HEATER WATER OUTLET HOSE A

(a) Install the heater water outlet hose A to the air conditioning unit with the clip. Text in Illustration *a View A *b UP Side *c -20 to 20 ° *d White Paint Mark HINT: Perform the installation with the hose clip and mark at the correct angle.

25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

(See page )

26. ADD ENGINE COOLANT

27. INSPECT FOR COOLANT LEAK

28. CHARGE REFRIGERANT

29. WARM UP ENGINE

30. INSPECT FOR REFRIGERANT LEAK

31. INSTALL NO. 1 ENGINE UNDER COVER

32. INSTALL V-BANK COVER SUB-ASSEMBLY

33. INSPECT FRONT DOOR PANEL SUB-ASSEMBLY LH

HINT:

Use the same procedure as for the RH side (See page ).

34. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY LH

HINT:

Use the same procedure as for the RH side (See page ).

35. INSPECT FRONT DOOR PANEL SUB-ASSEMBLY RH

36. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY RH