RM3660EC _58 Vehicle Interior _080733 HEATING / AIR CONDITIONING _0393729 AIR CONDITIONING UNIT(for Gasoline Model) A

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

PROCEDURE

Hide Display 1.TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

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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.

0.365,3.479 0.615,3.688 0.25,0.208 12 true *A 2.281,3.479 2.531,3.688 0.25,0.208 12 true *B

*A	for Automatic Air Conditioning System	*B	for Manual Air Conditioning System
	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).

0,0 0,0 false

	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.

for Manual Air Conditioning System:

Connect the connector.

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

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Hide Display 5.INSTALL AIR CONDITIONER UNIT ASSEMBLY

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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 each earth wire with each bolt.

1.385,1.531 0.438,1.083 0.438,1.083 0.604,0.479 true 6.073,1.719 6.073,1.385 true 3.635,4.885 3.896,4.688 true 3.167,4.542 3.406,4.771 0.24,0.229 10 true *A 0.198,1.021 0.406,1.208 0.208,0.188 10 true *a 6.01,1.729 6.219,1.917 0.208,0.188 10 true *a 3.906,4.594 4.115,4.781 0.208,0.188 10 true *a

*A	w/ PTC Heater	-	-
*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)

w/ PTC Heater:

Connect the earth wire with the bolt.

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

Connect each 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 LEVIN GT)

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 3 earth wires with 3 bolts.

1.104,1.625 0.458,1.781 0.458,1.781 0.604,0.51 true 5.781,0.927 6,1.417 true 0.198,1.708 0.417,1.927 0.219,0.219 10 true *a 5.542,0.823 5.76,1.042 0.219,0.219 10 true *a

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

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

Connect the connector.

Hide Display 8.CONNECT INSTRUMENT PANEL WIRE (for ALLION)

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 3 earth wires with 3 bolts.

0.917,1.521 1.125,0.344 1.125,0.344 0.427,0.313 true 6.01,1.74 5.927,1.333 true 1.167,0.24 1.417,0.406 0.25,0.167 10 true *a 5.896,1.74 6.146,1.906 0.25,0.167 10 true *a

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

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

Connect the connector.

Hide Display 9.INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for NR Series Engine)

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Hide Display 10.INSTALL POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU (except NR Series Engine)

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Hide Display 55308B 11.INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

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Hide Display 55990B 12.INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

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Hide Display 55086A 13.INSTALL CENTER HEATER TO REGISTER DUCT SUB-ASSEMBLY

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Hide Display 55215D 14.INSTALL NO. 3 DASH PANEL INSULATOR PAD

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Hide Display 58861B 15.INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Air Duct)

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Hide Display 58862B 16.INSTALL NO. 2 CONSOLE BOX DUCT (w/ Rear Air Duct)

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Hide Display 87212F 17.INSTALL REAR NO. 2 AIR DUCT

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Hide Display 87212J 18.INSTALL REAR NO. 5 AIR DUCT

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Hide Display 87212K 19.INSTALL REAR NO. 6 AIR DUCT

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Hide Display 87212G 20.INSTALL REAR NO. 3 AIR DUCT

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Hide Display 87212H 21.INSTALL REAR NO. 4 AIR DUCT

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Hide Display 58510D 22.CONNECT FRONT FLOOR CARPET ASSEMBLY

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Hide Display 58569D 23.INSTALL FRONT FLOOR CAUTION PLATE COVER

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Hide Display 77306 24.INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY

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Hide Display 88625Q 25.INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)

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Hide Display 82877 26.INSTALL ECU INTEGRATION BOX RH

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Hide Display 89340A 27.INSTALL CLEARANCE WARNING ECU ASSEMBLY (w/ TOYOTA Parking Assist-sensor System)

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Hide Display 28.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

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Hide Display 29.INSTALL STEERING COLUMN ASSEMBLY

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Hide Display 30.INSTALL FRONT SEAT ASSEMBLY LH

for Manual Seat:

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for Power Seat:

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Hide Display 31.INSTALL FRONT SEAT ASSEMBLY RH

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

Hide Display 88716A 32.CONNECT COOLER REFRIGERANT LIQUID PIPE A

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 8 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 33.CONNECT SUCTION PIPE SUB-ASSEMBLY

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 8 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.

0.771,1.396 1.385,1.083 true 1.646,1.771 1.875,1.969 0.229,0.198 10 true *a 0.542,1.313 0.76,1.521 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 34.CONNECT INLET HEATER WATER HOSE (except M15B-FKS, M15C-FKS)

1.396,3.469 1.167,2.958 false 0.198,2.417 0.5,2.688 0.302,0.271 10 false *a 1.01,2.854 1.281,3.063 0.271,0.208 10 false *b 2,3.115 2.26,3.344 0.26,0.229 10 false *c 2.198,2.573 2.5,2.792 0.302,0.219 10 false *d 1.479,0.865 1.667,1.063 0.188,0.198 10 true A

*a	View A
*b	Marking (White)
*c	Clip Installation Angle (90°)
*d	Clip Installation Angle (120°)

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 87245 35.CONNECT INLET HEATER WATER HOSE (for M15B-FKS, M15C-FKS)

1.469,3.469 1.24,2.958 false 0.198,2.417 0.5,2.688 0.302,0.271 10 false *a 1.083,2.885 1.354,3.094 0.271,0.208 10 false *b 2.031,3.094 2.292,3.323 0.26,0.229 10 false *c 2.25,2.563 2.552,2.781 0.302,0.219 10 false *d 1.396,0.844 1.583,1.042 0.188,0.198 10 true A

*a	View A
*b	Marking (Red)
*c	Clip Installation Angle (90°)
*d	Clip Installation Angle (135°)

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 (except M15B-FKS, M15C-FKS)

2.146,3.469 2.323,3.021 false 0.167,2.427 0.479,2.667 0.313,0.24 10 false *a 2.323,2.938 2.635,3.156 0.313,0.219 10 false *b 1.375,3.104 1.708,3.375 0.333,0.271 10 false *c 1.188,2.552 1.5,2.823 0.313,0.271 10 false *d 0.99,0.844 1.208,1.042 0.219,0.198 10 true A

*a	View A
*b	for NR Series Engine TFTM Made: Marking (White) for NR Series Engine GTMC Made: Marking (Green) for M20A-FKS, M20E-FKS: Marking (Yellow) for M20C-FKS: Marking (Blue)
*c	Clip Installation Angle (90°)
*d	Clip Installation Angle (120°)

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 87246 37.CONNECT OUTLET HEATER WATER HOSE (for M15B-FKS, M15C-FKS)

1.969,3.469 2.146,3.021 false 0.167,2.427 0.479,2.667 0.313,0.24 10 false *a 2.167,2.948 2.479,3.167 0.313,0.219 10 false *b 1.25,3.083 1.583,3.354 0.333,0.271 10 false *c 1.125,2.5 1.438,2.771 0.313,0.271 10 false *d 0.917,0.813 1.135,1.01 0.219,0.198 10 true A