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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating / Air Conditioning System - Service Information (1 Of 3) >> FRONT AIR CONDITIONING UNIT (for HV Model) >> Installation [12/2019 - 10/2022] >> Procedure

Installation [12/2019 - 10/2022]: Procedure

  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
  2. INSTALL CENTER HEATER TO REGISTER DUCT 
    1. Engage the 6 claws to install the center heater to register duct.
  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY 
    NOTE:
    • 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.
    1. Engage the 2 guides and claw to connect the ID code box (immobiliser code ECU) as shown in the illustration.
      GTY847026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Connect the 4 connectors.
      GTY924291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    3. Engage each clamp.
    4. Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.
    5. Install the 4 bolts (A).
      GTY916719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A) Bolt (B)
      Nut - -

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

    6. Connect the brake pedal assembly with the bolt (B).

      Torque: 15 N.m (153 kgf/cm, 11 ft.lbf) 

    7. Temporarily install the nut.
    8. Install the 3 bolts.

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

    9. Install the 2 hole plugs.
    10. Install a new cooler unit drain hose grommet.
      NOTE:
      • 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.
      GTY890819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lip
    11. Connect the drain cooler hose.
    12. Install the clip.
  4. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.

      Bolt 

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

      Nut 

      Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

    2. Temporarily install the screw.

      HINT: 

      Do not fully tighten the screw.

  5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY 
    1. Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

      Bolt 

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

      Nut 

      Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

    2. Temporarily install the screw.

      HINT: 

      Do not fully tighten the screw.

  6. INSTALL AIR CONDITIONER UNIT ASSEMBLY 
    1. Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.
      Fig 1: Air Conditioner Unit Assembly Bolts, Screws And Nut Tightening Sequence
      GTY879477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
      Nut - -

      Bolt 

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

      Nut 

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

      NOTE:

      Tighten the bolts, screws and nut in the order shown in the illustration.

  7. CONNECT INSTRUMENT PANEL WIRE 
    1. Connect the earth wire with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    2. Engage each clamp.
    3. Connect the 2 connectors.
    4. Engage each clamp.
    5. Install the 2 nuts.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

    6. Connect the connector holder with the bolt (B).

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

    7. Connect the 4 earth wires with the 4 bolts (A).

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

    8. Connect the connector.
  8. INSTALL CENTER HEATER TO REGISTER SUB DUCT 
    1. Engage the guide.
    2. Install the center heater to register sub duct with the 2 screws.
  9. INSTALL NO. 3 DASH PANEL INSULATOR PAD 
    1. Install the No. 3 dash panel insulator pad.
  10. INSTALL REAR NO. 3 AIR DUCT 
    1. Engage the 4 claws to install the rear No. 3 air duct.
  11. INSTALL REAR NO. 4 AIR DUCT 
    1. Engage the 4 claws.
    2. Install the rear No. 4 air duct with the clip.
    3. Install the front floor carpet assembly to the original position as shown in the illustration.
      GTY915605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 4 guides.
  12. INSTALL REAR NO. 1 AIR DUCT 
    1. Engage the 4 claws to install the rear No. 1 air duct.
  13. INSTALL REAR NO. 2 AIR DUCT 
    1. Engage the 4 claws.
    2. Install the rear No. 2 air duct with the clip.
    3. Install the front floor carpet assembly to the original position as shown in the illustration.
      GTY915639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 4 guides.
  14. INSTALL ACCELERATOR PEDAL 

    Refer to PROCEDURE - Step 1

  15. INSTALL ACCELERATOR PEDAL PAD 

    Refer to PROCEDURE - Step 2

  16. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR 
    1. Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.
  17. INSTALL NO. 1 CLEARANCE WARNING BUZZER 

    Refer to PROCEDURE - Step 1

  18. INSTALL PARKING ASSIST ECU WITH BRACKET 

    Refer to PROCEDURE - Step 3

  19. INSTALL ECU INTEGRATION BOX RH 

    Refer to PROCEDURE - Step 2

  20. INSTALL STEERING COLUMN ASSEMBLY 

    Refer to INSTALLATION [12/2019 - 10/2021] , or refer to INSTALLATION [10/2021 - 10/2022]

  21. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  22. INSTALL METER MIRROR SUB-ASSEMBLY (w/ Headup Display) 

    Refer to INSTALLATION [12/2019 - ]

  23. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU 

    Refer to INSTALLATION [12/2019 - 10/2022]

  24. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat) 

    Refer to INSTALLATION [12/2019 - 10/2022]

  25. INSTALL FRONT SEAT ASSEMBLY (for Power Seat) 

    Refer to INSTALLATION [12/2019 - 10/2022]

  26. CONNECT INLET HEATER WATER HOSE B 
    1. Connect the inlet heater water hose B with the marking facing left and engage the clip within the area shown in the illustration.
      GTY932130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (60°)
      *d 60°
      NOTE:

      Do not apply excessive force to the inlet heater water hose B.

  27. CONNECT OUTLET HEATER WATER HOSE B 
    1. Connect the outlet heater water hose B with the marking facing left and engage the clip within the area shown in the illustration.
      GTY853965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Yellow)
      *c Clip Installation Angle (270°)
      NOTE:

      Do not apply excessive force to the outlet heater water hose B.

  28. CONNECT COOLER REFRIGERANT LIQUID PIPE A 
    1. Remove the vinyl tape from the cooler refrigerant liquid pipe A.
    2. 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

    3. Install the O-ring to the cooler refrigerant liquid pipe A.
      NOTE:

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

    4. Connect the cooler refrigerant liquid pipe A.
  29. CONNECT SUCTION PIPE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the suction pipe sub-assembly.
    2. 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

    3. Install the O-ring to the suction pipe sub-assembly.
      NOTE:

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

    4. Connect the suction pipe sub-assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY916395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert the tube joint into the fitting hole securely and install the bolt.

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

  30. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  31. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 16

  32. INSTALL FRONT UPPER SUSPENSION TO COWL BRACE SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  33. INSTALL FRONT FENDER SPLASH SHIELD SEAL FRONT LH 

    Refer to PROCEDURE - Step 18

  34. INSTALL FRONT FENDER SPLASH SHEILD SEAL FRONT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  35. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR LH 

    Refer to PROCEDURE - Step 20

  36. INSTALL FENDER SPLASH SHIELD SUB-ASSEMBLY REAR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2019 - ]

  38. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  39. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    See step  2

  41. WARM UP COMPRESSOR 

    See step  4

  42. INSPECT FOR REFRIGERANT LEAK 

    See step  5

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