HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION; 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM1000000028T64
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [11/2022 - ]
Title: HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION; 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022 - ]

INSTALLATION

PROCEDURE

1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Engage the 2 claws.

(b) Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:

Be sure to support the air conditioner unit assembly when installing it. Failure to do so may cause the bracket of the air conditioner unit assembly to break.
When installing the air conditioner unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

(a) Engage the 2 guides and claw to connect the ID code box (immobiliser code ECU) as shown in the illustration.

Install in this Direction

(b) Connect each connector.

Install in this Direction

(d) Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

(e) Install the 4 bolts (A).

*A	for Manual Transaxle	-	-
	Bolt (A)		Bolt (B)
	Bolt (C)		Nut

Torque:

except G16E-GTS :

25 N·m {255 kgf·cm, 18 ft·lbf}

for G16E-GTS :

31 N·m {316 kgf·cm, 23 ft·lbf}

(f) Install the bolt (B).

Torque:

23.6 N·m {241 kgf·cm, 17 ft·lbf}

(g) for Manual Transaxle:

(1) Install the bolt (C).

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

(h) Temporarily install the nut.

(i) Install the 2 bolts.

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(j) Install a new cooler unit drain hose grommet.

NOTICE:

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.

Lip

(k) Connect the drain cooler hose.

(l) Install the front floor mat to its original position as shown in the illustration.

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

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

Torque:

Bolt :

20 N·m {204 kgf·cm, 15 ft·lbf}

Nut :

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(d) Install the front floor mat to its original position as shown in the illustration.

Move in this Direction

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

(a) Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

Torque:

Bolt :

20 N·m {204 kgf·cm, 15 ft·lbf}

Nut :

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(d) Connect the earth wire with the bolt.

Torque:

except G16E-GTS :

8.5 N·m {87 kgf·cm, 75 in·lbf}

for G16E-GTS :

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Install the front floor mat to its original position as shown in the illustration.

Move in this Direction

5. INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.

	Bolt		Screw
	Nut	-	-

Torque:

Bolt :

9.8 N·m {100 kgf·cm, 87 in·lbf}

Nut :

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

Tighten the bolts, screws and nut in the order shown in the illustration.

6. CONNECT INSTRUMENT PANEL WIRE

(a) Engage each clamp.

*a	Lock Lever
	Move in this Direction

(b) Temporarily connect the connector and then move the lock lever as shown in the illustration to securely connect the connector.

NOTICE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

(d) Engage each clamp.

(e) Connect the instrument panel wire with the screw.

Torque:

3.2 N·m {33 kgf·cm, 28 in·lbf}

(f) Connect the 3 earth wires with the 3 bolts.

Torque:

except G16E-GTS :

8.5 N·m {87 kgf·cm, 75 in·lbf}

for G16E-GTS :

10 N·m {102 kgf·cm, 7 ft·lbf}

(g) w/ PTC Heater:

(1) Connect the earth wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(h) Connect each connector.

(i) Connect the instrument panel wire with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(j) Connect the relay block holder with the 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

7. INSTALL POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU

Click here

8. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

(a) Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

Torque:

Bolt :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut :

6.0 N·m {61 kgf·cm, 53 in·lbf}

9. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Engage the guide and 6 claws to install the lower defroster nozzle assembly.

10. INSTALL CENTER HEATER TO REGISTER DUCT SUB-ASSEMBLY

(a) Install the center heater to register duct sub-assembly with the 2 clips.

(b) Engage the clamp.

11. INSTALL NO. 3 DASH PANEL INSULATOR PAD

(a) Install the No. 3 dash panel insulator pad with 2 new clips as shown in the illustration.

12. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.

Install in this Direction

13. INSTALL REAR NO. 5 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 2 claws to install the rear No. 5 air duct as shown in the illustration.

Install in this Direction

14. INSTALL REAR NO. 6 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 2 claws to install the rear No. 6 air duct as shown in the illustration.

Install in this Direction

15. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct)

Install in this Direction

(a) Engage the 2 claws to install the rear No. 3 air duct as shown in the illustration.

16. INSTALL REAR NO. 4 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 2 claws to install the rear No. 4 air duct as shown in the illustration.

Install in this Direction

17. CONNECT FRONT FLOOR CARPET ASSEMBLY

(a) for LH Side:

(1) Install the front floor carpet assembly to its original position as shown in the illustration.

(2) Engage the 2 guides.

(3) Install the 3 front floor carpet clips.

(b) for RH Side:

(1) Install the front floor carpet assembly to its original position as shown in the illustration.

(2) Engage the 2 guides.

(3) w/ clip.

Install the 2 front floor carpet clips.

(4) Install the front floor carpet clip.

18. INSTALL FRONT FLOOR CAUTION PLATE COVER

(a) Engage the guide and claw to install the front floor caution plate cover as shown in the illustration.

	Install in this Direction (1)
	Install in this Direction (2)

19. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY (for Sedan)

Click here

20. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY (for Hatchback)

Click here

21. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)

(a) Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.

22. INSTALL ECU INTEGRATION BOX RH

Click here

23. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

24. INSTALL STEERING COLUMN ASSEMBLY

Click here

25. INSTALL FRONT SEAT ASSEMBLY LH

for Manual Seat:

Click here

for Power Seat:

Click here

26. INSTALL FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

27. CONNECT COOLER REFRIGERANT LIQUID PIPE A (except G16E-GTS)

(a) w/o Sub-cool Accelerator:

(1) Remove the vinyl tape from the cooler refrigerant liquid pipe A.

(2) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe A.

Refrigerant	Compressor Oil
for Gasoline Model	ND-OIL 12 or equivalent
for HV Model	ND-OIL 11 or equivalent

(3) Install the O-ring to the cooler refrigerant liquid pipe A.

NOTICE:

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

(4) Connect the cooler refrigerant liquid pipe A.

28. CONNECT SUCTION PIPE SUB-ASSEMBLY (except G16E-GTS)

(a) w/o Sub-cool Accelerator:

(1) Remove the vinyl tape from the suction pipe sub-assembly.

(2) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

Refrigerant	Compressor Oil
for Gasoline Model	ND-OIL 12 or equivalent
for HV Model	ND-OIL 11 or equivalent

(3) Install the O-ring to the suction pipe sub-assembly.

NOTICE:

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

(4) Connect the suction pipe sub-assembly.

(5) Rotate the hook connector as shown in the illustration.

(6) Insert the tube joint into the fitting hole securely and temporarily install the bolt.

(7) Using a union nut wrench, tighten the bolt.

Torque:

Specified tightening torque :

9.8 N·m {100 kgf·cm, 87 in·lbf}

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
8.6 N*m (88 kgf*cm, 76 in.*lbf)

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

(b) w/ Sub-cool Accelerator:

(1) Remove the vinyl tape from the suction pipe sub-assembly.

(2) Sufficiently apply compressor oil to a 2 new O-rings and the fitting surfaces of the suction pipe sub-assembly.

Refrigerant	Compressor Oil
for Gasoline Model	ND-OIL 12 or equivalent
for HV Model	ND-OIL 11 or equivalent

(3) Install the 2 O-rings to the suction pipe sub-assembly.

NOTICE:

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

(4) Connect the suction pipe sub-assembly.

(5) Rotate the hook connector as shown in the illustration.

(6) Insert the tube joint into the fitting hole securely and temporarily install the bolt.

(7) Using a union nut wrench, tighten the bolt.

Torque:

Specified tightening torque :

9.8 N·m {100 kgf·cm, 87 in·lbf}

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
8.6 N*m (88 kgf*cm, 76 in.*lbf)

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

29. CONNECT NO. 2 AIR CONDITIONING TUBE & ACCESSORY ASSEMBLY (for G16E-GTS)

(a) Remove the vinyl tape from the No. 2 air conditioner tube and accessory assembly.

(b) Sufficiently apply compressor oil to a 2 new O-rings and the fitting surfaces of the No. 2 air conditioner tube and accessory assembly.

Compressor Oil:

ND-OIL 12 or equivalent

NOTICE:

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

(d) Connect the No. 2 air conditioner tube and accessory assembly.

(e) Rotate the hook connector as shown in the illustration.

(f) Insert the tube joint into the fitting hole securely and temporarily install the bolt.

(g) Using a union nut wrench, tighten the bolt.

Torque:

Specified tightening torque :

9.8 N·m {100 kgf·cm, 87 in·lbf}

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
8.6 N*m (88 kgf*cm, 76 in.*lbf)

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

30. CONNECT INLET HEATER WATER HOSE (for Gasoline Model)

(a) except G16E-GTS:

(1) Connect the inlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

Do not apply excessive force to the inlet heater water hose.

*a	View A
*b	for TMC Made and M20A-FKS: Marking (Green) for TMMMS Made and M20A-FKS: Marking (White)
*c	Clip Installation Angle (90°)
*d	Clip Installation Angle (120°)

(b) for G16E-GTS:

(1) Connect the inlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

Do not apply excessive force to the inlet heater water hose.

*a	View A
*b	Marking (White)
*c	Clip Installation Angle (120°)

31. CONNECT OUTLET HEATER WATER HOSE (for Gasoline Model)

(a) except G16E-GTS:

(1) Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

Do not apply excessive force to the outlet heater water hose.

*a	View A
*b	for TMC Made and M20A-FKS: Marking (Green) for TMMMS Made and M20A-FKS: Marking (Yellow)
*c	Clip Installation Angle (90°)
*d	Clip Installation Angle (120°)

(b) for G16E-GTS:

(1) Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

Do not apply excessive force to the outlet heater water hose.

*a	View A
*b	Marking (Green)
*c	Clip Installation Angle (150°)

32. CONNECT INLET HEATER WATER HOSE (for HV Model)

(a) Connect the inlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

Do not apply excessive force to the inlet heater water hose.

*a	View A
*b	Marking (Blue)
*c	Clip Installation Angle (120°)

33. CONNECT OUTLET HEATER WATER HOSE (for HV Model)

(a) Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration.

NOTICE:

Do not apply excessive force to the outlet heater water hose.

*a	View A
*b	Marking (PINK)
*c	Clip Installation Angle (120°)

34. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

except G16E-GTS:

Click here

for G16E-GTS:

Click here

35. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

except G16E-GTS:

Click here

for G16E-GTS:

Click here

36. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

37. ADD ENGINE COOLANT

for M20A-FKS, Fully Sealed Type: Click here

for M20A-FKS, for Non-Fully Sealed Type: Click here

for 2ZR-FXE: Click here

for G16E-GTS: Click here

38. INSPECT FOR COOLANT LEAK

for M20A-FKS, Fully Sealed Type: Click here

for M20A-FKS, Non-Fully Sealed Type: Click here

for 2ZR-FXE: Click here

for G16E-GTS: Click here

39. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))

Click here

40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFO-1234yf(R1234yf))

Click here

41. WARM UP ENGINE (for Gasoline Model)

Click here

42. WARM UP COMPRESSOR (for HV Model)

for HFC-134a(R134a): Click here

for HFO-1234yf(R1234yf): Click here

43. INSPECT FOR REFRIGERANT LEAK (for HFC-134a(R134a))

Click here

44. INSPECT FOR REFRIGERANT LEAK (for HFO-1234yf(R1234yf))

Click here