Operation CHARM: Car repair manuals for everyone.
Home >> Toyota Truck >> 2011 >> Highlander 4WD V6-3.5L (2GR-FXE) Hybrid >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Removal and Replacement >> Front Cooling Unit >> Installation

Installation





AIR CONDITIONING: FRONT COOLING UNIT: INSTALLATION

1. INSTALL AIR CONDITIONING UNIT

(a) Install the air conditioning unit with the 3 bolts.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

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

2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

(a) Driver Side:

(1) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.

Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

(b) Passenger Side:

(1) Using a 12 mm hexagon wrench, adjust the position of the 2 collars.

Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

(2) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "TORX" bolts.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(c) Connect the connector.





(d) Install the 2 bolts and 2 caps to the engine compartment side.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(e) Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(f) Engage the cooler drain hose.





(g) Connect the blower motor connector.

(h) Install the 2 nuts and bolt.

(i) Connect each connector.

(j) Connect the 2 earth wires with the 2 bolts [A].

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(k) Engage each clamp.





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

(a) Install the 3 nuts.





(b) Install the 2 bolts.

(c) Install the No. 1 instrument panel brace sub-assembly with the screw.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(d) Engage each clamp.





(e) Connect the earth wire with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

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

(a) Install the 3 nuts.





(b) Install the bolt.

(c) Install the No. 2 instrument panel brace sub-assembly with the screw.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(d) Engage each clamp.





(e) Connect the earth wire with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

5. INSTALL CENTER HEATER TO REGISTER DUCT

(a) Engage the 4 claws and install the center heater to register duct.





(b) Engage the clamp.

6. INSTALL REAR NO. 3 AIR DUCT

(a) Engage the 2 claws and install the rear No. 3 air duct.





(b) Install the clip.

(c) Engage the claw and install the floor carpet.





7. INSTALL REAR NO. 1 AIR DUCT

(a) Engage the 2 claws and install the rear No. 1 air duct.





(b) Install the clip.

(c) Engage the clamp.

(d) Engage the claw and install the floor carpet.





8. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Installation

9. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) Installation

10. INSTALL POWER STEERING ECU ASSEMBLY Installation

11. CONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY

(a) Connect the instrument panel junction block assembly with the 3 nuts.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)





12. INSTALL STEERING COLUMN ASSEMBLY Installation

13. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation

14. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY Installation

15. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY Installation

16. INSTALL PUSH ROD PIN Installation

17. INSTALL BRAKE PEDAL RETURN SPRING Installation

18. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation

19. INSPECT AND ADJUST BRAKE PEDAL HEIGHT Adjustments

20. INSPECT BRAKE PEDAL FREE PLAY Adjustments

21. INSPECT BRAKE PEDAL RESERVE DISTANCE Adjustments

22. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY Installation

23. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Installation

24. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation

25. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) Installation

26. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation

27. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) Installation

28. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation

29. INSTALL FRONT PILLAR GARNISH RH Installation

30. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation

31. INSTALL FRONT PILLAR GARNISH LH Installation

32. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation

33. INSTALL POWER SWITCH (w/ Smart Key System) Installation

34. INSTALL FRONT NO. 2 CONSOLE BOX INSERT Installation

35. INSTALL FRONT NO. 1 CONSOLE BOX INSERT Installation

36. INSTALL CONSOLE BOX ASSEMBLY Removal

37. INSTALL LOWER REAR CONSOLE BOX Installation

38. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY Installation

39. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation

40. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

41. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH Installation

42. INSTALL FRONT DOOR SCUFF PLATE RH Installation

43. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation

44. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation

45. INSTALL FRONT DOOR SCUFF PLATE LH Installation

46. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System) Installation

47. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) Installation

48. INSTALL HEATER CONTROL AND ACCESSORY ASSEMBLY (for Manual Air Conditioning System) Installation

49. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System) Installation

50. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/o Smart Key System) Installation

51. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/ Smart Key System) Installation

52. INSTALL CENTER INSTRUMENT PANEL REGISTER ASSEMBLY Installation

53. INSTALL COMBINATION METER ASSEMBLY Installation

54. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY Installation

55. POSITION FRONT WHEELS STRAIGHT AHEAD

56. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation

57. INSTALL STEERING COLUMN COVER Installation

58. ADJUST SPIRAL CABLE SUB-ASSEMBLY Installation

59. INSTALL STEERING WHEEL ASSEMBLY Installation

60. INSPECT STEERING WHEEL CENTER POINT

61. INSTALL STEERING PAD Installation

62. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation

63. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation

64. INSTALL FRONT WHEEL LH Installation

65. CONNECT COOLER REFRIGERANT LIQUID PIPE A

(a) Remove the attached vinyl tape from the pipe.

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

Compressor oil:

ND-OIL 11 or equivalent

NOTICE:
* Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.
* Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

(c) Install the O-ring on the cooler refrigerant liquid pipe A.

(d) Install the cooler refrigerant liquid pipe A.

66. CONNECT NO. 1 COOLER REFRIGERANT SUCTION PIPE

(a) Remove the attached vinyl tape from the pipe.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant suction pipe.

Compressor oil:

ND-OIL 11 or equivalent

NOTICE:
* Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.
* Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

(c) Install the O-ring on the No. 1 cooler refrigerant suction pipe.

(d) Move the hook connector in the direction indicated by the arrow in the illustration.





(e) Insert the pipe joint into the fitting hole securely and tighten the bolt.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

67. CONNECT HEATER WATER INLET HOSE

(a) Install the heater inlet water hose and attach the clip.





68. CONNECT HEATER WATER OUTLET HOSE

(a) Install the heater outlet water hose and attach the clip.





69. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY Installation

70. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

71. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

72. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

73. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

74. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

75. INSPECT STEERING PAD Installation

76. INSPECT SRS WARNING LIGHT

(a) Inspect the SRS warning light Check Mode Procedure.

77. ADD ENGINE COOLANT (for Engine) Coolant (for Engine)

78. INSPECT FOR COOLANT LEAK (for Engine) Cooling System

79. CHARGE WITH REFRIGERANT Service and Repair

80. WARM UP ENGINE Service and Repair

81. INSPECT FOR REFRIGERANT LEAK Service and Repair
pro multis · About Operation CHARM