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Installation





AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY

(a) Provisionally install the air conditioning unit assembly.

(b) Insert the bracket hook into the holes of the reinforcement bracket, and provisionally install the reinforcement.

(c) Install the instrument panel reinforcement with the 7 bolts.

(d) Install the 2 caps.





(e) Install the 5 bolts.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

NOTICE:
Tighten the bolts in the sequence order shown in the illustration to install the air conditioner unit assembly.

(f) Install the 2 nuts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(g) Engage the 20 clamps.





(h) Connect the connector.

(i) Connect the 2 airbag connectors Service Precautions.

(j) Install the 3 bolts.





(k) Engage the 2 clamps and connect the 6 connectors to the air conditioning unit assembly.





2. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY

(a) Install the air conditioner amplifier assembly with the nut.





Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

(b) Connect the connector.

3. INSTALL TRANSPONDER KEY ECU ASSEMBLY

(a) Install the transponder key ECU assembly with the nut.





(b) Connect the connector.

4. INSTALL DRIVER SIDE JUNCTION BLOCK

(a) Install the driver side junction block assembly with the 2 nuts.





Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Install the bracket with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

5. INSTALL ECM (for 2TR-FE) Installation

6. INSTALL ECM (for 1GR-FE) Installation

7. INSTALL PARKING BRAKE CONTROL LEVER ASSEMBLY (for Lever Type Parking Brake) Installation

8. INSTALL STEERING COLUMN ASSEMBLY Installation

9. INSTALL STEERING SLIDING YOKE Installation

10. INSTALL STEERING COLUMN HOLE COVER Installation

11. INSTALL NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET

(a) Install the instrument panel brace mounting bracket RH with the bolt and nut.





(b) Install the instrument panel brace mounting bracket LH with the bolt and nut.





12. INSTALL AIR DUCT ASSEMBLY RH

(a) Engage the 3 claws and install the air duct assembly.





13. INSTALL AIR DUCT ASSEMBLY LH

(a) Engage the 4 claws and install the air duct assembly heater.





(b) Engage the clip.

14. INSTALL NO. 1 REAR AIR DUCT (for Double Cab)

(a) Engage the 2 claws and install the air duct rear.





(b) Put the floor carpet back down.

15. INSTALL NO. 2 REAR AIR DUCT (for Double Cab)

(a) Engage the 2 claws and install the air duct rear.





(b) Put the floor carpet back down.

16. INSTALL NO. 3 HEATER TO REGISTER DUCT

(a) Install the heater to register duct with the nut.





17. INSTALL NO. 1 HEATER REGISTER DUCT

(a) Install the heater to register duct with the nut.





18. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY W/ PASSENGER AIRBAG ASSEMBLY Installation

19. CONNECT PASSENGER AIRBAG CONNECTOR

20. INSTALL INSTRUMENT SIDE PANEL RH Installation

21. INSTALL INSTRUMENT LOWER COVER SUB-ASSEMBLY Installation

22. INSTALL LOWER INSTRUMENT PANEL LH Installation

23. INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH Installation

24. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation

25. INSTALL INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY Installation

26. INSTALL COMBINATION METER ASSEMBLY Installation

27. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation

28. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL Installation

29. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY Reassembly

30. INSTALL RADIO RECEIVER ASSEMBLY Installation

31. INSTALL AIR CONDITIONING CONTROL ASSEMBLY Installation

32. INSTALL FRONT CONSOLE BOX (for Manual Transmission on Bench Seat Type) Installation

33. INSTALL FRONT CONSOLE BOX (for Automatic Transmission on Bench Seat Type) Installation

34. INSTALL FRONT CONSOLE BOX (for Manual Transmission on Separate Seat Type) Installation

35. INSTALL FRONT CONSOLE BOX (for Automatic Transmission on Separate Seat Type) Installation

36. INSTALL INSTRUMENT PANEL CUP HOLDER TRAY (for Automatic Transmission on Separate Seat Type) Installation

37. INSTALL REAR CONSOLE BOX ASSEMBLY (for Separate Seat Type) Installation

38. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Manual Transmission on Separate Seat Type) Installation

39. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Automatic Transmission on Separate Seat Type) Installation

40. INSTALL INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake) Installation

41. INSTALL INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake) Installation

42. INSTALL FRONT PILLAR GARNISH LH (for Regular Cab) Installation

43. INSTALL FRONT PILLAR GARNISH LH (for Access Cab) Installation

44. INSTALL FRONT PILLAR GARNISH LH (for Double Cab) Installation

45. INSTALL FRONT PILLAR GARNISH RH (for Regular Cab) Installation

46. INSTALL FRONT PILLAR GARNISH RH (for Access Cab) Installation

47. INSTALL FRONT PILLAR GARNISH RH (for Double Cab) Installation

48. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH

49. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH

50. INSTALL COWL SIDE TRIM BOARD LH (for Regular Cab) Installation

51. INSTALL COWL SIDE TRIM BOARD LH (for Access Cab) Installation

52. INSTALL COWL SIDE TRIM BOARD LH (for Double Cab) Installation

53. INSTALL COWL SIDE TRIM BOARD RH (for Regular Cab) Installation

54. INSTALL COWL SIDE TRIM BOARD RH (for Access Cab) Installation

55. INSTALL COWL SIDE TRIM BOARD RH (for Double Cab) Installation

56. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) Installation

57. INSTALL FRONT DOOR SCUFF PLATE LH (for Access Cab) Installation

58. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) Installation

59. INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) Installation

60. INSTALL FRONT DOOR SCUFF PLATE RH (for Access Cab) Installation

61. INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab) Installation

62. INSTALL FRONT FLOOR FOOTREST Installation

63. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY Installation

64. INSTALL SPIRAL CABLE SUB-ASSEMBLY Installation

65. CENTER SPIRAL CABLE Installation

66. INSTALL STEERING COLUMN COVER UPPER Installation

67. INSTALL STEERING COLUMN COVER LOWER Installation

68. INSTALL STEERING WHEEL ASSEMBLY Installation

69. INSTALL HORN BUTTON ASSEMBLY Installation

70. INSTALL NO. 2 STEERING WHEEL COVER LOWER Installation

71. INSTALL NO. 3 STEERING WHEEL COVER LOWER Installation

72. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

73. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

74. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

75. INSTALL FRONT WIPER ARM RH Installation

76. INSTALL FRONT WIPER ARM LH Installation

77. INSTALL FRONT WIPER ARM HEAD CAP Installation

78. INSTALL HEATER WATER OUTLET HOSE (for 2TR-FE)

(a) Install the heater water outlet hose onto the heater unit.





NOTICE:
Make sure that the hose clip and mark are at the correct angle when installing.

79. INSTALL HEATER WATER OUTLET HOSE (for 1GR-FE)

(a) Install the heater water outlet hose onto the heater unit.





NOTICE:
Make sure that the hose clip and mark are at the correct angle when installing.

80. INSTALL HEATER WATER INLET HOSE (for 2TR-FE)

(a) Install the heater water inlet hose onto the heater unit.





NOTICE:
Make sure that the hose clip and mark are at the correct angle when installing.

81. INSTALL HEATER WATER INLET HOSE (for 1GR-FE)

(a) Install the heater water inlet hose onto the heater unit.





NOTICE:
Make sure that the hose clip and mark are at the correct angle when installing.

82. INSTALL AIR CONDITIONING TUBE ASSEMBLY

(a) Apply compressor oil to 2 new O-rings and install them onto the hose.





Compressor oil:

RL-897 or equivalent

(b) Install the air conditioner tube and piping clamp.

HINT
Check that the claw of the piping clamp is correctly fitted.

(c) Install the bracket with the bolt and 2 clamps.





Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

83. INSTALL SUCTION HOSE SUB-ASSEMBLY

(a) Apply compressor oil to 2 new O-rings and install them onto the pipe.





Compressor oil:

RL-897 or equivalent

(b) Install the suction hose and piping clamp.

HINT
Check that the claws of the piping clamp are correctly fitted.

(c) Install the bracket with the 2 bolts.





Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

84. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

85. ADD ENGINE COOLANT (for 2TR-FE) Service and Repair

86. ADD ENGINE COOLANT (for 1GR-FE) Service and Repair

87. CHECK FOR ENGINE COOLANT LEAK (for 2TR-FE) Testing and Inspection

88. CHECK FOR ENGINE COOLANT LEAK (for 1GR-FE) Service and Repair

89. CHARGE REFRIGERANT Service and Repair

90. WARM UP ENGINE Service and Repair

91. CHECK FOR REFRIGERANT LEAK Service and Repair

92. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

93. INSPECT SRS WARNING LIGHT

Diagnosis System
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