Toyota Urban Cruiser 2009 Owner's Manual

URBAN CRUISER

(RHD)

AIR CONDITIONING

ENGLISH

EUROPE

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INTRODUCTION

IMPORTANT NOTICE

This manual has been designed for technicians who are qualified and educated in the proper procedures of vehicle safety, handling and maintenance; experienced in installation of car air conditioning or who are able to carry out installation procedures when given instructions by an experienced technician in a supervisory capacity; and are certified to handling refrigerant.

1. Take special care to ensure that clearance between air conditioning components and other components such as brake parts, fuel system and electric wires as specified in this manual.

2. If a problem is found with the air conditioning system due to installation, refer back to the manual to correct the problem(s).

3. Vehicle and air conditioning kit components as well as installation procedures are subject to change without prior notice. Refer to the latest installation manual and service information. Any changes affecting the above items will be given in the form of a “Installation instructions for air conditioning (Supplement)” (issued by DENSO) or a service bulletin (issued by the manufacturer).

DEFINITION OF TERMS

WARNING

CAUTION

NOTE

FRONT,REAR

:Describes precautions that should be observed in order to prevent injury or death to the user during installation.

:Describes precautions that should be observed in order to prevent damage to the vehicle or its components, which may occur during installation if insufficient care is taken.

:Provides additional information that facilitates installation work.

:Shows the direction when viewed from the driver's seat.

LEFT,RIGHT

FOREWORD

This manual has been published to explain how to install the air conditioning for TOYOTA URBAN CRUISER. When installing the air conditioning, installation should be performed as described in this manual.

[APPLICATION VEHICLE]

VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITION

URBAN CRUISER NSP110R 2009.1~ 1NR-FE RHD

CAUTION

Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation.

[DOCUMENT CODE AND DOCUMENT PART NUMBER]

MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBER

GENERAL INFORMATION /

AFTER INSTALLATION

00503436E* 988963-680*

1. INSTALLATION INSIDE PASSENGER COMPARTMENT

CAUTION

1. Be sure to use the correct oil, refrigerant and charging/recovery equipment.

2. Before starting installation, read all "PRECAUTIONS FOR SAFETY INSTALLATION" thoroughly and follow the instructions described in it.

3. Before starting installation, remove the negative terminal of the battery and ensure seat/floor covers are in position.

4. Take care not to scratch any parts of the vehicle.

5. Sort removed bolts and tapping screws into groups so that they can be reassembled correctly.

HOOKS

FRONT

VEHICLE HARNESS

Disconnect the negative terminal first.

BATTERY

CAUTION

First remove the negative terminal of the battery and the vehicle harness connection before installing the equipment.

A009347

(1) REMOVAL OF ORIGINAL PARTS-1

(a) Scuff plate (LH)

SCUFF PLATE (LH)

HOOKS

A029314

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HOOKS

(b) Cowl side panel (LH)

COWL SIDE PANEL (LH)

LEFT SIDE OF THE GLOVE BOX

DAMPER PORTION

BOSS

NOTE 1, 2

GLOVE BOX

LOCK PORTION

BOSS

NOTE 1, 2

A029268

NOTE

Remove the glove box in the following order.

1. Press in the sides of the glove box.

2. Bypass the bosses.

3. Lift.

A029176

FRONT

GLOVE BOX

HOOKS

GUIDE

SCREW (REUSE)

INSTRUMENT PANEL UNDER COVER (LH)

HOOKS NOTE 3

 VEHICLE WITH INSTRUMENT PANEL UNDER

COVER (LH) ONLY [(d)]

(d) Instrument panel under cover (LH) (e) Screw (for instrument panel)

A029322

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BOLT (REUSE)

(f) Bolt (for instrument panel)

A029269

PASSENGER AIRBAG CANCEL SWITCH

AIRBAG CONNECTOR CLIP

HOOK

AIRBAG CONNECTOR

FRONT

A029439

INSTRUMENT PANEL UNDER COVER (RH)

 VEHICLE WITH PASSENGER AIRBAG CAN-

CEL SWITCH ONLY [(g)-(h)]

(g) Airbag connector clip (h) Disconnect the connection of the airbag

connector.

 VEHICLE WITH INSTRUMENT PANEL UNDER

COVER (RH) ONLY [(i)]

(i) Instrument panel under cover (RH)

:GUIDE :HOOK

GUIDE

A029270

INSTRUMENT PANEL LOWER COVER

FRONT

 VEHICLE WITHOUT KNEE AIRBAG ONLY

[(j)]

(j) Instrument panel lower cover

A029326

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 VEHICLE WITH KNEE AIRBAG ONLY [(k)]

(k) Instrument panel lower cover

CAUTION

Wear a pair of Kevlar gloves before starting work.

:GUIDE :HOOK

FRONT

CLIPS

INSTRUMENT PANEL LOWER COVER

FRONT

CENTER CLUSTER PANEL

NOTE

1. To ease work, insert your hand from under the instrument panel lower cover to the other side of the panel and release the projections on the upper part of the bracket from the holes on the panel.

2. Release the projections one by one.

A029177

(l) Center cluster panel

CLIPS

FRONT

CLIPS

HEATER CONTROL PANE L

HOOKS

CLIPS

A029178

(m) Heater control panel (lift up only)

CLIPS

A029179

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SHIFT COVER

HOOKS

FRONT

(n) Shift cover

HOOKS

SHIFT PANEL

HOOKS

FRONT

HOOKS

CONSOLE BOX COVER

A029180

(o) Shift panel

FRONT

HOOKS

CLIPS

A029181

(p) Console box cover

NOTE

Disconnect the connector of the console box cover from the vehicle harness.

: HOOK

A029315

(q) Console box carpet (r) Console box

CONSOLE BOX

CONSOLE BOX CARPET

A029182

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GUIDE

CENTER CLUSTER LOWER COVER

CLIP

GUIDE

(s) Center cluster lower cover

FRONT

A029183

VEHICLE HARNESS CLAMP

BOLT ( REUSE)

FRONT

FLOOR CARPET (LH)

FRONT

A029184

(t) Bolt (reuse) (u) Vehicle harness clamp

(v) Floor carpet (LH)

FRONT

HOOKS

TURN OVER

A029446

SILENCER MAT (LH)

A029299

(w) Silencer mat (LH)

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WEATHER STRIP (LH)

FRONT

(x) Weather strip (LH)

A029185

(y) Filter cover

FRONT

FILTER

FRONT

BLOWER MOTOR

FILTER COVER

VEHICLE HARNESS CLAMP

A029186

A029187

FRONT

(z) Filter

(2) REMOVAL OF ORIGINAL PARTS-2

(a) Disconnect the vehicle harness from the blower

motor.

(b) Disconnect the vehicle harness from the blower

resistor. (c) Three vehicle harness clamps (d) Vinyl tape (discard)

VEHICLE HARNESS

BLOWER RESISTOR

VEHICLE HARNESS

VINYL TAPE (DISCARD)

VEHICLE HARNESS CLAMPS

A009590

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FRONT

ORIGINAL FOOT AIR DUCT (LH) (DISCARD)

BLOWER UNIT

BLOWER UNIT UPPER CASE

(e) Original foot air duct (LH) (discard)

HOOKS

HOOK

A001867

(f) Two screws (for blower unit lower case)

BLOWER UNIT LOWER CASE

BLOWER UNIT LEG

FRONT

SCREWS (REUSE)

SCREW (REUSE)

A029170

BLOWER UNIT LOWER CASE

A029437

SCREW (REUSE)

(g) blower unit leg

NOTE

Pull the blower unit lower case toward the back of the body and remove the blower unit leg.

(h) Two screws (for blower unit lower case) (i) Bolt (for blower unit lower case)

BLOWER UNIT LOWER CASE

BOLT (REUSE)

A029317

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FRONT

(j) Blower unit lower case

BLOWER UNIT LOWER CASE

CAUTION

Be careful not to damage the blower unit lower case when removing the blower unit lower case.

[1]

[2]

[3]

VEHICLE HARNESS (16-P)

VINYL TAPE (DISCARD)

VEHICLE HARNESS (16-P)

VEHICLE HARNESS CLAMP

BLOWER UNIT LOWER CASE

VEHICLE HARNESS CLAMP

VEHICLE HARNESS

A029171

FRONT

A029473

FRONT

 VEHICLE WITHOUT ORIGINAL AMPLIFIER

ONLY [(k) ~ (l)]

(k) Vinyl tape (discard) (l) Vehicle harness clamp

 VEHICLE WITH ORIGINAL AMPLIFIER ONLY

[(m) ~ (n)]

(m) Disconnect the vehicle harness from the original

amplifier. (n) Vehicle harness clamp

ORIGINAL AMPLIFIER

A029284

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VIEW:A

(o) Original amplifier (discard)

FRONT

VIEW:A

ORIGINAL AMPLIFIER (DISCARD)

ORIGINAL AMPLIFIER

(DISCARD)

[1]

ORIGINAL SCREW

(DISCARD)

FRONT

[2]

AIRBAG HARNESS

AIRBAG ECU

ORIGINAL BOLTS (DISCARD)

A029283

(p) Airbag ECU

FRONT

WARNING

1. Before starting work always check the cautions and warnings for the SRS airbag system.

2. Make sure the ignition switch is OFF (LOCK) position.

3. Make sure the negative terminal is removed from the battery.

4. If installing airbag sensor assy CTR without disconnecting the negative terminal of the battery, airbag may open if there is an impact on it. Make sure that the negative terminal of the battery is disconnected before installation.

5. Wait at least 90 seconds after negative terminal is disconnected to start installation.

6. Do not disconnect the airbag harness from the airbag ECU when removing the airbag ECU.

7. Put down the airbag ECU in a way that minimizes the force on the airbag harness.

8. Do not subject the airbag sensor to any shocks or force.

A029324

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HEATER UNIT LOWER CASE

SCREWS (REUSE)

FRONT

A001868

(q) Two screws (for heater unit lower case)

FRONT

HEATER UNIT LOWER CASE

FRONT

[1]

SCREW (REUS

HOOKS

(r) Screw (for heater unit lower case)

A029189

(s) Remove the catch of pawl.

CAUTION

Unhook the catch of pawl and keep as it is. (Do not pull the pawl forcibly because it is easily damaged.)

[2]

[1]

FRONT

HEATER UNIT LOWER CASE

A029447

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FRONT

(t) Drain hose

DRAIN HOSE

PULL OUT

HEATER UNIT LOWER CASE

A001874

FRONT

HEATER UNIT INNER COVER (DISCARD)

HEATER UNIT LOWER CASE

A001875

(u) Heater unit lower case

(v) Heater unit inner cover (discard)

HEATER UNIT LOWER CASE

A001876

ORIGINAL PACKING (DISCARD)

PACKING

(INCLUDED IN A/C KIT)

HEATER UNIT LOWER CASE

A009581

(w) Remove and discard a packing from the heater

unit lower case.

(x) Attach a packing (included in A/C kit) to the

heater unit lower case.

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EVAPORATOR

(3) THERMISTOR

(a) Assemble the evaporator to the heater unit lower

case.

HEATER UNIT LOWER CASE

THERMISTOR

A001877

(b) Assemble the thermistor to the evaporator.

CAUTION

1. It shall be only one time to insert the thermistor into the evaporator.

2. When inserting the thermistor into the evaporator again, shift the thermistor one column from the position where one was inserted previously.

34mm

THERMISTOR CONNECTOR

EVAPORATOR

50mm

A009577

unit lower case.

HEATER UNIT LOWER CASE

A029474

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INSTRUMENT PANEL

[1]

(4) REINSTALLATION OF THE HEATER UNIT

LOWER CASE

(a) Insert the heater unit lower case into the

instrument panel.

[2]

HEATER UNIT LOWER CASE

A029172

(b) Insert the heater unit lower case.

INSTRUMENT PANEL

A009585

- 14 -

00503437E

case into A and B and C on the heater unit upper case respectively.

NOTE

Insert the piping unit of evaporator into the vehicle hole.

HEATER UNIT LOWER CASE

HEATER UNIT

UPPER CASE

NOTE

A029271

(d) Reinstall the heater unit lower case to the heater

unit upper case.

CAUTION

Be sure not to damage the evaporator fins.

FRONT

NOTE

HOOKS

NOTE

Be careful that the pawl at the vehicle side of a heater unit shall not be locked.

HEATER UNIT LOWER CASE

FRONT

A029318

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FRONT

HEATER UNIT LOWER CASE

(e) Reinstall the screw for the heater unit lower case

of left side.

HEATER UNIT LOWER CASE

INSTRUMENT

PANEL

SCREW (REUS

SCREWS (REUSE)

[2]

A029285

FRONT

A001868

BLOWER UNIT LOWER CASE

(f) Reinstall two screws for the heater unit lower

case of right side.

(5) REINSTALLATION OF THE BLOWER UNIT

LOWER CASE

(a) Insert the blower unit lower case into the

instrument panel.

[1]

A029173

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00503437E

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