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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 (2 Of 3) >> FRONT AIR CONDITIONING UNIT (for Gasoline Model) >> Installation [10/2022 - 11/2023] >> Procedure

Installation [10/2022 - 11/2023]: Procedure

  1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  2. INSTALL CENTER HEATER TO REGISTER DUCT 

    Refer to PROCEDURE - Step 2

  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 3

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

    Refer to PROCEDURE - Step 4

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

    Refer to PROCEDURE - Step 5

  6. INSTALL AIR CONDITIONER UNIT ASSEMBLY 

    Refer to PROCEDURE - Step 6

  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. w/ PTC Heater:
      1. Connect the earth wire with the bolt (A).

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

      2. Connect the connector.
    8. Connect the 4 earth wires with the 4 bolts (A).

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

    9. Connect the connector.
  8. INSTALL CENTER HEATER TO REGISTER SUB DUCT 

    Refer to PROCEDURE - Step 8

  9. INSTALL NO. 3 DASH PANEL INSULATOR PAD 

    Refer to PROCEDURE - Step 9

  10. INSTALL REAR NO. 3 AIR DUCT 

    Refer to PROCEDURE - Step 10

  11. INSTALL REAR NO. 4 AIR DUCT 

    Refer to PROCEDURE - Step 11

  12. INSTALL REAR NO. 1 AIR DUCT 

    Refer to PROCEDURE - Step 12

  13. INSTALL REAR NO. 2 AIR DUCT 

    Refer to PROCEDURE - Step 13

  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 (for Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 16

  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 [10/2022 - 11/2023]

  21. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY 

    See 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 [10/2022 - 11/2023]

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

    Refer to INSTALLATION [10/2022 - 11/2023]

  25. INSTALL FRONT SEAT ASSEMBLY (for Power Seat) 

    Refer to INSTALLATION [10/2022 - 11/2023]

  26. CONNECT INLET HEATER WATER HOSE B 
    1. Connect the inlet heater water hose B with the marking facing up and engage the clip within the area shown in the illustration.
      GTY1119862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Purple)
      *c Clip Installation Angle (270°)
      NOTE:

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

  27. CONNECT OUTLET HEATER WATER HOSE B (w/o Stop And Start System) 
    1. Connect the outlet heater water hose B with the marking facing up and engage the clip within the area shown in the illustration.
      GTY1121263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (270°)
      NOTE:

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

  28. CONNECT OUTLET HEATER WATER HOSE A (w/ Stop And Start System) 
    1. Connect the outlet heater water hose A with the marking facing up and engage the clip within the area shown in the illustration.
      GTY1120789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Marking (Green)
      *c Clip Installation Angle (270°)
      NOTE:

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

  29. CONNECT NO. 2 AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY 
    1. Remove the vinyl tape from the No. 2 air conditioner tube and accessory assembly.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the No. 2 air conditioner tube and accessory assembly.

      Compressor Oil

      ND-OIL 12 or equivalent

    3. Install the O-rings to the No. 2 air conditioner tube and accessory assembly.
      NOTE:

      Keep the O-rings and O-ring fitting surfaces free from dirt and foreign matter.

    4. Connect the No. 2 air conditioner tube and accessory assembly.
    5. Rotate the hook connector as shown in the illustration.
      GTY1121987Courtesy 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 SHIELD 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 

    Refer to PROCEDURE - Step 2

  39. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  41. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  42. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

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