Toyota CH-R Service Manual: Installation

INSTALLATION

PROCEDURE

1. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Engage the claws to install the lower defroster nozzle assembly.

2. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

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

NOTICE:

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.

(a) Engage the guides to install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

Install in this Direction

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(b) Connect 2 connectors.

(c) Engage the clamps.

(d) Install the 5 bolts.

Torque:

Bolt A :

25 N·m {255 kgf·cm, 18 ft·lbf}

Bolt B :

23.6 N·m {241 kgf·cm, 17 ft·lbf}

(e) Temporarily install the nut.

(f) Install the 2 bolts.

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

4. CONNECT DRAIN COOLER HOSE

(a) Connect the drain cooler hose. NOTICE: If the cooler unit drain hose grommet is disconnected from the vehicle body while connecting the drain cooler hose, make sure to replace it with a new one. Failure to do so may cause water ingress.

*1 Cooler Unit Drain Hose Grommet

5. INSTALL INSTRUMENT PANEL WIRE

(a) Engage clamps and hook to connect the instrument panel wire.

*a

Clamp

*b

Hook

(b) Install the instrument panel junction block assembly with main body ECU with the bolt and nut.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(c) Install the 4 ground wires with the 4 bolts.

Torque:

Bolt A :

10.5 N·m {107 kgf·cm, 8 ft·lbf}

Bolt B (Part No. 90119-06995) :

10.5 N·m {107 kgf·cm, 8 ft·lbf}

Bolt B (Part No. 90119-06915) :

8.5 N·m {87 kgf·cm, 75 in·lbf}

Bolt B (Part No. 90119-06A07) :

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Install the bolt and screw.

Torque:

Bolt :

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Connect each connector.

6. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

(a) Install the No. 3 instrument panel to cowl brace sub-assembly with the nut and bolt. Torque: Bolt : 10 N·m {102 kgf·cm, 7 ft·lbf} Nut : 6.0 N·m {61 kgf·cm, 53 in·lbf}

(b) Engage the claws and clamps.

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

(a) Install the No. 2 instrument panel brace sub-assembly with the bolt and nut. Torque: Bolt : 20 N·m {204 kgf·cm, 15 ft·lbf} Nut : 18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(c) Install the ground wire with the bolt.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

(d) Engage the clamps to connect the wire harness.

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

(a) Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

Torque:

Bolt :

20 N·m {204 kgf·cm, 15 ft·lbf}

Nut :

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(c) Engage the clamps to connect the wire harness.

(d) Install the relay block assembly with the 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Install the bolt to connect the ground wire.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

9. INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Tighten the 3 bolts, 2 screws and nut in the order shown in the illustration to install the air conditioner unit.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

10. INSTALL REAR NO. 1 AIR DUCT

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

Install in this Direction

11. INSTALL REAR NO. 2 AIR DUCT

(a) Engage the claws to install the rear No. 2 air duct as shown in the illustration.

Install in this Direction

12. INSTALL REAR NO. 3 AIR DUCT

(a) Engage the claws to install the rear No. 3 air duct as shown in the illustration.

Install in this Direction

13. INSTALL REAR NO. 4 AIR DUCT

(a) Engage the claws to install the rear No. 4 air duct as shown in the illustration.

Install in this Direction

(b) Install the front floor carpet assembly to its original position as shown in the illustration.

Install in this Direction

(c) Engage the clamps.

(d) Install the clip.

(e) Install the 2 front floor carpet clips.

14. INSTALL REAR NO. 5 AIR DUCT

(a) Engage the claws to install the rear No. 5 air duct as shown in the illustration.

Install in this Direction

15. INSTALL REAR NO. 6 AIR DUCT

(a) Engage the claws to install the rear No. 6 air duct as shown in the illustration.

Install in this Direction

16. INSTALL NO. 3 DASH PANEL INSULATOR PAD

(a) Engage the clips to install the No. 3 dash panel insulator pad.

(b) Install the front floor carpet assembly to its original position as shown in the illustration.

Install in this Direction

(c) Engage the clamps.

(d) Install the clip.

(e) Install the 2 front floor carpet clips.

17. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)

(a) Connect the aspirator and connector to install the cooler thermistor (room temperature sensor).

18. INSTALL ECU INTEGRATION BOX RH

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19. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY

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20. INSTALL STEERING COLUMN ASSEMBLY

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21. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

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22. INSTALL FRONT SEAT ASSEMBLY LH

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23. INSTALL FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

24. CONNECT COOLER REFRIGERANT LIQUID PIPE A

(a) Remove the vinyl tape from the cooler refrigerant liquid pipe A.

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

Compressor Oil:

ND-OIL 12 or equivalent

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

NOTICE:

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

(d) Install the bolt and the cooler refrigerant liquid pipe A.

25. CONNECT SUCTION PIPE SUB-ASSEMBLY

(a) Remove the vinyl tape from the suction pipe sub-assembly.

(b) Apply sufficient compressor oil to a new O-ring and fitting surface of the suction pipe sub-assembly.

Compressor Oil:

ND-OIL 12 or equivalent

(c) Install the O-ring to the suction pipe sub-assembly.

NOTICE:

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

(d) Connect the suction pipe sub-assembly.

(e) Rotate the hook connector as shown in the illustration.

Install in this Direction

(f) Insert the hose joint into the fitting hole securely and install the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

26. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose with the marking (pink) facing up and engage the clip within the area shown in the illustration. NOTICE: Do not apply excessive force to the inlet heater water hose.

*a View A *b Marking (Pink) *c Clip Installation Angle (120°)

27. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose with the marking (blue) facing up and engage the clip within the area shown in the illustration. NOTICE: Do not apply excessive force to the outlet heater water hose.

*a View A *b Marking (Blue) *c Clip Installation Angle (120°)

28. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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29. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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30. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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31. INSTALL WATER GUARD PLATE LH

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32. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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33. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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34. ADD ENGINE COOLANT

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35. INSPECT FOR COOLANT LEAK

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36. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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37. WARM UP ENGINE

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38. INSPECT FOR REFRIGERANT LEAK

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39. INITIALIZATION SERVO MOTOR

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