RM3660EC _58 Vehicle Interior _080733 HEATING / AIR CONDITIONING _0393728 AIR CONDITIONING UNIT(for HV Model) A

HEATING / AIR CONDITIONING AIR CONDITIONING UNIT(for HV Model) INSTALLATION

PROCEDURE

Hide Display 1.TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

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

Hide Display 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.

Connect each connector.

0,0 0,0 false

Install in this Direction

Engage each clamp.

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

Install the 4 bolts (A).

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	Bolt (A)		Bolt (B)
	Nut	-	-

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

Install the bolt (B).

Torque:: 23.6 N*m (241 kgf*cm, 17 ft.*lbf)

Temporarily install the nut.

Install the 2 bolts.

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

0.302,0.719 0.438,0.552 false 0.135,0.625 0.354,0.833 0.219,0.208 10 false *a

Lip

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.

Connect the drain cooler hose.

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

Hide Display 55307C 3.INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

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)

Temporarily install the screw.

HINT:: Do not fully tighten the screw.

Engage each clamp.

0,0 0,0 false

Move in this Direction

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

Hide Display 55306A 4.INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

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)

Temporarily install the screw.

HINT:: Do not fully tighten the screw.

Engage each clamp.

Connect the earth wire with the bolt.

Torque:: 8.8 N*m (90 kgf*cm, 78 in.*lbf)

0,0 0,0 false

Move in this Direction

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

Hide Display 5.INSTALL AIR CONDITIONER UNIT ASSEMBLY

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

0.594,0.479 0.75,0.677 0.156,0.198 10 true 1 6.396,0.469 6.552,0.667 0.156,0.198 10 true 2 2.604,0.479 2.76,0.677 0.156,0.198 10 true 3 1.354,5.333 1.51,5.531 0.156,0.198 10 true 4 2.896,5.188 3.052,5.385 0.156,0.198 10 true 5 5.271,4.531 5.427,4.729 0.156,0.198 10 true 6

	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.

Hide Display 6.CONNECT INSTRUMENT PANEL WIRE (for COROLLA, LEVIN)

0.542,0.698 1.51,0.24 true 1.552,0.146 1.781,0.365 0.229,0.219 10 true *a

*a	Lock Lever
	Move in this Direction

Engage each clamp.

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.

Check that there is no looseness in the installed parts of the airbag sensor with ECU assembly.

Engage each clamp.

Connect the instrument panel wire with the screw.

Torque:: 3.2 N*m (33 kgf*cm, 28 in.*lbf)

Connect the 3 earth wires with the 3 bolts.

1.24,1.406 0.375,1.167 0.375,1.167 0.521,0.448 true 6.177,1.583 6.177,1.25 true 0.167,1.052 0.354,1.25 0.188,0.198 10 true *a 6.135,1.583 6.323,1.781 0.188,0.198 10 true *a

*a	Earth Wire	-	-
	Bolt (A)		Bolt (B)

Torque:: Bolt (A) : 8.8 N*m (90 kgf*cm, 78 in.*lbf); Bolt (B) : 8.5 N*m (87 kgf*cm, 75 in.*lbf)

Connect the connector.

Connect the instrument panel wire with the bolt.

Torque:: 8.8 N*m (90 kgf*cm, 78 in.*lbf)

Connect the relay block holder with the 2 nuts.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Hide Display 7.CONNECT INSTRUMENT PANEL WIRE (for ALLION)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>AIR CONDITIONING UNIT (for Gasoline Model)>INSTALLATION202304,999999,_58,_080733,_0393729,RM100000002B1I3_02_0243,

Hide Display 8.INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for NR Series Engine)

Click herePower Source / Network>POWER DISTRIBUTION>MAIN BODY ECU>INSTALLATION202304,999999,_57,_080742,_0392832,RM100000002B2HK_01_0052,

Hide Display 9.INSTALL POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU (except NR Series Engine)

Click herePower Source / Network>POWER DISTRIBUTION>MAIN BODY ECU>INSTALLATION202304,999999,_57,_080742,_0392832,RM100000002B2HK_01_0061,

Hide Display 55308B 10.INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

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)

Hide Display 55990B 11.INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

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

Hide Display 55086A 12.INSTALL CENTER HEATER TO REGISTER DUCT SUB-ASSEMBLY

w/o Navigation System:

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

ii.

Engage the clamp.

w/ Navigation System:

Install the center heater to register duct sub-assembly with the 3 clips.

Hide Display 55215D 13.INSTALL NO. 3 DASH PANEL INSULATOR PAD

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

Hide Display 58861B 14.INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Air Duct)

Engage the 2 claws to install the No. 1 console box duct.

Hide Display 58862B 15.INSTALL NO. 2 CONSOLE BOX DUCT (w/ Rear Air Duct)

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

Install the No. 2 console box duct as shown in the illustration.

Install the clip.

Hide Display 87212F 16.INSTALL REAR NO. 2 AIR DUCT

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Install in this Direction

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

Hide Display 87212J 17.INSTALL REAR NO. 5 AIR DUCT

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Install in this Direction

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

Hide Display 87212K 18.INSTALL REAR NO. 6 AIR DUCT

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Install in this Direction

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

Hide Display 87212G 19.INSTALL REAR NO. 3 AIR DUCT

0,0 0,0 false

Install in this Direction

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

Hide Display 87212H 20.INSTALL REAR NO. 4 AIR DUCT

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Install in this Direction

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

Hide Display 58510D 21.CONNECT FRONT FLOOR CARPET ASSEMBLY

for LH Side:

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

ii.

Engage the 2 guides.

iii.

Install the 3 front floor carpet clips.

for RH Side:

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

ii.

Engage the 2 guides.

iii.

Install the 3 front floor carpet clips.

Hide Display 58569D 22.INSTALL FRONT FLOOR CAUTION PLATE COVER

0,0 0,0 false

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

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

Hide Display 77306 23.INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY

Click hereVehicle Exterior>DOOR / HATCH>LUGGAGE DOOR LOCK CONTROL CABLE ASSEMBLY>INSTALLATION201906,999999,_59,_080735,_0392107,RM100000001HO1L_01_0148,

Hide Display 88625Q 24.INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR

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

Hide Display 82877 25.INSTALL ECU INTEGRATION BOX RH

Click herePower Source / Network>NETWORKING>NETWORK GATEWAY ECU>INSTALLATION202304,999999,_57,_080743,_0392834,RM100000002B1AZ_01_0032,

Hide Display 89340A 26.INSTALL CLEARANCE WARNING ECU ASSEMBLY (w/ TOYOTA Parking Assist-sensor System)

Click hereAudio / Visual / Telematics>PARK ASSIST / MONITORING>CLEARANCE WARNING ECU>INSTALLATION202307,999999,_56,_080754,_0394056,RM100000002CWQQ_01_0018,

Hide Display 27.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click hereVehicle Interior>INTERIOR PANELS / TRIM>INSTRUMENT PANEL SAFETY PAD>INSTALLATION202304,999999,_58,_080744,_0393716,RM100000002B101,

Hide Display 28.INSTALL STEERING COLUMN ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION202304,999999,_55,_080762,_0391589,RM100000002BCU7,

Hide Display 29.INSTALL FRONT SEAT ASSEMBLY LH

for Manual Seat:

Click hereVehicle Interior>SEAT>FRONT SEAT ASSEMBLY (for Manual Seat)>INSTALLATION202307,999999,_58,_080732,_0391517,RM100000002CW4C,

for Power Seat:

Click hereVehicle Interior>SEAT>FRONT SEAT ASSEMBLY (for Power Seat)>INSTALLATION202307,999999,_58,_080732,_0391518,RM100000002CW4E,

Hide Display 30.INSTALL FRONT SEAT ASSEMBLY RH

HINT:: Use the same procedure as for the LH side.

Hide Display 88716A 31.CONNECT COOLER REFRIGERANT LIQUID PIPE A (for 8ZR-FXE)

Remove the vinyl tape from the cooler refrigerant liquid pipe A.

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

Compressor Oil:: ND-OIL 11 or equivalent

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.

Connect the cooler refrigerant liquid pipe A.

Hide Display 88707 32.CONNECT SUCTION PIPE SUB-ASSEMBLY (for 8ZR-FXE)

Remove the vinyl tape from the suction pipe sub-assembly.

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

Compressor Oil:: ND-OIL 11 or equivalent

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

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

Connect the suction pipe sub-assembly.

Rotate the hook connector as shown in the illustration.

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

0.927,1.448 1.542,1.135 true 1.75,1.802 1.979,2 0.229,0.198 10 true *a 0.698,1.354 0.917,1.563 0.219,0.208 10 true *b

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

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 hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201906,999999,_V1,_080724,_0393249,RM100000001HWSK,

·

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)

Hide Display 88710E 33.CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (except 8ZR-FXE)

Remove the vinyl tape from 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 11 or equivalent

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

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

Connect the air conditioning tube and accessory assembly.

Hide Display 88707B 34.CONNECT SUCTION TUBE SUB-ASSEMBLY B (except 8ZR-FXE)

Remove the vinyl tape from the suction tube sub-assembly B.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction tube sub-assembly B.

Compressor Oil:: ND-OIL 11 or equivalent

Install the O-ring to the suction tube sub-assembly B.

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

Connect the suction tube sub-assembly B.

Rotate the hook connector as shown in the illustration.

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

0.927,1.448 1.542,1.135 true 1.75,1.802 1.979,2 0.229,0.198 10 true *a 0.698,1.354 0.917,1.563 0.219,0.208 10 true *b

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

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 hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201906,999999,_V1,_080724,_0393249,RM100000001HWSK,

·

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)

Hide Display 87245 35.CONNECT INLET HEATER WATER HOSE (for 8ZR-FXE)

1.49,3.292 1.302,2.99 false 1.135,0.885 1.313,1.094 0.177,0.208 10 true A 1.177,2.844 1.448,3.042 0.271,0.198 10 false *b 2.302,3.167 2.615,3.385 0.313,0.219 10 false *c 0.365,2.26 0.646,2.521 0.281,0.26 10 false *a

*a	View A
*b	for TFTM Made: Marking (Pink) for GTMC Made: Marking (Blue)
*c	Clip Installation Angle (60°)

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.

Hide Display 87246 36.CONNECT OUTLET HEATER WATER HOSE (for 8ZR-FXE)

2.042,3.313 2.219,2.865 false 0.208,2.323 0.521,2.563 0.313,0.24 10 false *a 2.156,2.677 2.469,2.896 0.313,0.219 10 false *b 1.083,3.177 1.417,3.448 0.333,0.271 10 false *c 1.344,0.958 1.563,1.156 0.219,0.198 10 true A

*a	View A
*b	Marking (Pink)
*c	Clip Installation Angle (60°)

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.

Hide Display 87209 37.CONNECT WATER HOSE SUB-ASSEMBLY (except 8ZR-FXE)

Connect the water hose sub-assembly with the marking facing up and engage the hose clips within the area shown in the illustration.

2.115,2.844 2.552,2.781 true 4.698,2.76 5.146,2.844 true 0.958,2 1.292,2.333 0.333,0.333 10 false *a 2.573,2.698 2.885,2.854 0.313,0.156 10 false *c 1.51,2.26 1.823,2.417 0.313,0.156 10 false *e 2.917,0.865 3.083,1.073 0.167,0.208 10 true A 1.604,2.552 1.917,2.708 0.313,0.156 10 false *f 4.104,2.01 4.438,2.344 0.333,0.333 10 false *b 4.51,2.656 4.76,2.906 0.25,0.25 10 false *d 5.583,2.26 5.833,2.51 0.25,0.25 10 false *e 5.531,2.583 5.781,2.833 0.25,0.25 10 false *f 3.313,1.031 3.479,1.24 0.167,0.208 10 true B