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Air Conditioning Unit: Installation: Installation

WARNING: This page is about a different car, the 2011 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL BLOWER ASSEMBLY (w/o PTC Heater) 
    1. Install the blower assembly with the 3 screws.
      Fig 1: Locating Blower Assembly And Screws
      GTY207480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Automatic Air Conditioning System:
      1. Connect the connector.
  2. INSTALL BLOWER ASSEMBLY (w/ PTC Heater) 
    1. Install the blower assembly with the 3 screws.
      Fig 2: Locating Blower Assembly And Screws
      GTY167404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the quick heater connector and install the screw.
    3. for Automatic Air Conditioning System:
      1. Connect the connector.
    4. Engage each clamp.
      Fig 3: Identifying Blower Assembly Clamp
      GTY187814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY 
    1. Engage the 2 claws and install the No. 2 air duct sub-assembly.
      Fig 4: Identifying No 2 Air Duct Sub-Assembly And Claws
      GTY207479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT 
    1. Temporarily tighten the air conditioning unit with the bolt and the nut.
      Fig 5: Locating Air Conditioning Unit With Bolt And Nut
      GTY169056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
      • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Manual Air Conditioning System) 
    1. Install the instrument panel reinforcement assembly with the 7 bolts.

      <A> 

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

      Fig 6: Identifying Instrument Panel Reinforcement Assembly With Bolts
      GTY188303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector.
    3. Engage each clamp.
    4. Engage the wire harness and junction block with the 12 bolts.

      <A> 

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    5. Engage the cooler drain hose.
      Fig 7: Locating Wire Harness And Junction Block With Bolts
      GTY208571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage each clamp and the wire harness.
      Fig 8: Identifying Wire Harness And Clamp
      GTY208568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Automatic Air Conditioning System) 
    1. Install the instrument panel reinforcement assembly with the 7 bolts.

      <A> 

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

      Fig 9: Identifying Instrument Panel Reinforcement Assembly With Bolts
      GTY188303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector.
    3. Engage each clamp.
    4. Engage the wire harness and junction block with the 12 bolts.

      <A> 

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    5. Engage the cooler drain hose.
      Fig 10: Locating Wire Harness And Junction Block With Bolts
      GTY208572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage each clamp and the wire harness.
      Fig 11: Identifying Wire Harness And Clamp
      GTY178434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL AIR CONDITIONING UNIT 
    1. Install the 3 bolts.
      Fig 12: Locating Instrument Panel Reinforcement Assembly And Bolts
      GTY208570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      HINT: 

      Tighten the bolts in the order shown in the illustration.

    2. Install the bolt.
      Fig 13: Locating Air Conditioning Unit With Bolt And Nut
      GTY207478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    3. Install the air conditioning unit with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  8. INSTALL HEATER COVER (w/ Cover) 
    1. Engage the 4 claws and install the heater cover.
      Fig 14: Identifying Heater Cover And Claws
      GTY207426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR NO. 1 AIR DUCT (w/ Rear Air Duct) 
    1. Engage the 4 claws and install the rear No. 1 air duct.
      Fig 15: Identifying Rear No 1 Air Duct And Claws
      GTY207427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 2 instrument panel brace sub-assembly with the bolt, screw and the nut.
      Fig 16: Identifying No 2 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      GTY207425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Screw 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. for TMC Made:
      1. Engage the clamp.
        Fig 17: Identifying No 2 Instrument Panel Brace Sub-Assembly And Clamp
        GTY208567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. except TMC Made:
      1. Engage each clamp.
        Fig 18: Identifying No 2 Instrument Panel Brace Sub-Assembly And Clamp
        GTY182999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Manual Air Conditioning System) 
    1. Install the No. 1 instrument panel brace sub-assembly with the bolt, screw and the nut.
      Fig 19: Identifying No 1 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      GTY208483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Screw 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. for TMC Made:
      1. Engage each clamp.
        Fig 20: Locating No 1 Instrument Panel Brace Sub-Assembly And Connector (TMC Made)
        GTY208610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the connector.
    3. except TMC Made:
      1. Engage each clamp.
        Fig 21: Locating No 1 Instrument Panel Brace Sub-Assembly And Connector (TMC And NUMMI Made)
        GTY208566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the connector.
  12. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Automatic Air Conditioning System) 
    1. Install the No. 1 instrument panel brace sub-assembly with the bolt, screw and the nut.
      Fig 22: Identifying No 1 Instrument Panel Brace Sub-Assembly With Bolt And Nut
      GTY208483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Screw 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. for TMC Made:
      1. Engage each clamp.
        Fig 23: Identifying No 1 Instrument Panel Brace Sub-Assembly And Clamp
        GTY183155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. except TMC Made:
      1. Engage each clamp.
        Fig 24: Identifying No 1 Instrument Panel Brace Sub-Assembly And Clamp
        GTY179865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct) 
    1. Engage the 2 claws to install the rear No. 3 air duct.
      Fig 25: Identifying Rear No. 3 Air Duct And Claws
      GTY185416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the clip and install the floor carpet.
      Fig 26: Identifying Floor Carpet And Clip
      GTY176163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct) 
    1. Engage the 2 claws to install the rear No. 2 air duct.
      Fig 27: Identifying Rear No. 2 Air Duct And Claws
      GTY207422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the clip and install the floor carpet.
      Fig 28: Identifying Floor Carpet And Clip
      GTY188586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE 
    1. Install the center instrument panel to cowl brace with the 2 bolts.
      Fig 29: Locating Center Instrument Panel To Cowl Brace And Bolts
      GTY207423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY 
    1. Engage the 6 claws and install the lower defroster nozzle assembly.
      Fig 30: Identifying Lower Defroster Nozzle Assembly And Claws
      GTY208565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY 
    1. Install the No. 1 air duct sub-assembly with the 2 nuts.
      Fig 31: Locating No 1 Air Duct Sub-Assembly Nuts
      GTY208564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  18. INSTALL SMART KEY ECU ASSEMBLY (w/ Smart Key System)  . Refer to INSTALLATION - Step 1
  19. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY  . Refer to INSTALLATION - Step 1
  20. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY  . Refer to INSTALLATION - Step 1
  21. INSTALL CONSOLE BOX ASSEMBLY (for Manual Transaxle)  . Refer to INSTALLATION - Step 2
  22. INSTALL CONSOLE BOX ASSEMBLY (for Automatic Transaxle)  . Refer to INSTALLATION - Step 1
  23. INSTALL CONSOLE BOX CARPET  . Refer to INSTALLATION - Step 3
  24. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY  . Refer to INSTALLATION - Step 5
  25. INSTALL NO. 1 SWITCH HOLE BASE (w/o Smart Key System)  . Refer to INSTALLATION - Step 7
  26. INSTALL NO. 1 SWITCH HOLE BASE (w/ Smart Key System)  . Refer to INSTALLATION - Step 8
  27. INSTALL FRONT NO. 1 CONSOLE BOX INSERT  . Refer to INSTALLATION - Step 10
  28. INSTALL COWL SIDE TRIM BOARD LH  . Refer to INSTALLATION - Step 53
  29. INSTALL FRONT DOOR SCUFF PLATE LH  . Refer to INSTALLATION - Step 54
  30. INSTALL FRONT NO. 2 CONSOLE BOX INSERT  . Refer to INSTALLATION - Step 13
  31. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover)  . Refer to INSTALLATION - Step 14
  32. INSTALL COWL SIDE TRIM BOARD RH  . Refer to INSTALLATION - Step 57
  33. INSTALL FRONT DOOR SCUFF PLATE RH  . Refer to INSTALLATION - Step 58
  34. INSTALL AIR CONDITIONING PANEL ASSEMBLY (for Manual Air Conditioning System)  . Refer to INSTALLATION - Step 1
  35. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System)  . Refer to INSTALLATION - Step 1
  36. INSTALL INSTRUMENT PANEL HOLE COVER  . Refer to INSTALLATION - Step 19
  37. INSTALL INSTRUMENT PANEL BOX ASSEMBLY  . Refer to INSTALLATION - Step 20
  38. INSTALL CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle)  . Refer to INSTALLATION - Step 21
  39. INSTALL CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle)  . Refer to INSTALLATION - Step 22
  40. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  . Refer to INSTALLATION - Step 23
  41. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle)  . Refer to INSTALLATION - Step 24
  42. INSTALL RADIO RECEIVER WITH BRACKET (w/o Navigation System)  . Refer to INSTALLATION - Step 4
  43. INSTALL NAVIGATION RECEIVER WITH BRACKET (w/ Navigation System)  . Refer to INSTALLATION - Step 4
  44. INSTALL STEERING POST ASSEMBLY (for 2ZR-FE)  . Refer to INSTALLATION - Step 2
  45. INSTALL STEERING POST ASSEMBLY (for 2AZ-FE)  . Refer to INSTALLATION - Step 3
  46. TURN FRONT WHEELS FACING STRAIGHT AHEAD 
  47. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  . Refer to INSTALLATION - Step 5
  48. INSTALL STOP LIGHT SWITCH ASSEMBLY  . Refer to INSTALLATION - Step 1
  49. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY  . Refer to INSTALLATION - Step 7
  50. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT  . Refer to INSTALLATION - Step 8
  51. INSTALL COLUMN HOLE COVER SILENCER SHEET  . Refer to INSTALLATION - Step 9
  52. INSTALL TRANSPONDER KEY AMPLIFIER (w/o Smart Key System)  . Refer to INSTALLATION - Step 10
  53. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 12
  54. INSTALL UPPER STEERING COLUMN COVER  . Refer to INSTALLATION - Step 13
  55. INSTALL LOWER STEERING COLUMN COVER  . Refer to INSTALLATION - Step 14
  56. TURN FRONT WHEELS FACING STRAIGHT AHEAD 
  57. ADJUST SPIRAL CABLE  . Refer to INSTALLATION - Step 7
  58. INSTALL STEERING WHEEL ASSEMBLY (w/o Front Spoiler) 

    Refer to INSTALLATION

  59. INSTALL STEERING WHEEL ASSEMBLY (w/ Front Spoiler) 

    Refer to INSTALLATION

  60. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY  . Refer to INSTALLATION - Step 9
  61. INSTALL POWER STEERING ECU ASSEMBLY (for 2ZR-FE)  . Refer to INSTALLATION - Step 2
  62. INSTALL POWER STEERING ECU ASSEMBLY (for 2AZ-FE)  . Refer to INSTALLATION - Step 2
  63. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY  . Refer to INSTALLATION - Step 1
  64. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY  . Refer to INSTALLATION - Step 7
  65. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH  . Refer to INSTALLATION - Step 52
  66. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY  . Refer to INSTALLATION - Step 4
  67. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH  . Refer to INSTALLATION - Step 56
  68. INSTALL NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY  . Refer to INSTALLATION - Step 6
  69. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  . Refer to INSTALLATION - Step 7
  70. INSTALL FRONT PILLAR GARNISH LH  . Refer to INSTALLATION - Step 61
  71. INSTALL FRONT PILLAR GARNISH RH  . Refer to INSTALLATION - Step 62
  72. INSTALL COMBINATION METER ASSEMBLY  . Refer to INSTALLATION - Step 1
  73. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY  . Refer to INSTALLATION - Step 2
  74. INSTALL CENTER INSTRUMENT PANEL REGISTER ASSEMBLY  . Refer to INSTALLATION - Step 12
  75. INSTALL INSTRUMENT PANEL FINISH PANEL END LH  . Refer to INSTALLATION - Step 13
  76. INSTALL INSTRUMENT PANEL FINISH PANEL END RH  . Refer to INSTALLATION - Step 14
  77. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH  . Refer to INSTALLATION - Step 15
  78. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL RH  . Refer to INSTALLATION - Step 16
  79. INSTALL HEATER OUTLET WATER HOSE 
    1. Install the water hose and attach the clip.
      Fig 32: Locating Heater Inlet Water Hose
      GTY208563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL HEATER INLET WATER HOSE 

    HINT: 

    Use the same procedure described for the heater outlet water hose.

  81. INSTALL AIR CONDITIONING TUBE ASSEMBLY 
    1. Remove the attached vinyl tape from the tube.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring on the air conditioning tube assembly.
    4. Install the air conditioning tube assembly.
  82. INSTALL SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the hose.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring on the suction hose sub-assembly.
    4. Move the hook connector in the direction indicated by the arrow in the illustration.
      Fig 33: Identifying Pipe Joint Into Fitting Hole And Bolt
      GTY208562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  83. INSTALL OUTER COWL TOP PANEL (for TMC Made)  . Refer to INSTALLATION - Step 13
  84. INSTALL OUTER COWL TOP PANEL (except TMC Made)  . Refer to INSTALLATION - Step 14
  85. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to INSTALLATION - Step 3
  86. INSTALL COWL TOP VENTILATOR LOUVER LH  . Refer to INSTALLATION - Step 4
  87. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER  . Refer to INSTALLATION - Step 5
  88. INSTALL HOOD TO COWL TOP SEAL  . Refer to INSTALLATION - Step 6
  89. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to INSTALLATION - Step 7
  90. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to INSTALLATION - Step 8
  91. INSTALL FRONT WIPER ARM HEAD CAP  . Refer to INSTALLATION - Step 9
  92. CHARGE WITH REFRIGERANT  See step  2
  93. ADD ENGINE COOLANT (for 2ZR-FE)  . Refer to REPLACEMENT - Step 2
  94. ADD ENGINE COOLANT (for 2AZ-FE)  . Refer to REPLACEMENT - Step 2
  95. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  96. INSPECT FOR COOLANT LEAK (for 2ZR-FE)  . Refer to ON-VEHICLE INSPECTION - Step 1
  97. INSPECT FOR COOLANT LEAK (for 2AZ-FE)  . Refer to ON-VEHICLE INSPECTION - Step 1
  98. INSPECT STEERING PAD  . Refer to INSTALLATION - Step 8
  99. INSPECT SRS WARNING LIGHT 

    Refer to DIAGNOSIS SYSTEM

  100. WARM UP ENGINE  See step  3
  101. INSPECT FOR REFRIGERANT LEAK  See step  4
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