AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. INSTALL DRAIN COOLER HOSE


    1. A01W0GIE04
      Text in Illustration
      *a Hose Notch
      *b Rib

      Align the hose notch and rib as shown in the illustration and install the drain cooler hose.

  2. INSTALL ASPIRATOR PIPE


    1. Engage the 2 claws to install the aspirator pipe.

  3. INSTALL COOLER THERMISTOR HOSE


    1. Install the cooler thermistor hose.

    2. Engage the clamp.

  4. INSTALL HEATER PACKING


    1. A01W5BN

      Install the heater packing as shown in the illustration.

  5. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A01W0XX

      Engage the guide and 2 claws to install the No. 4 air duct sub-assembly as shown in the illustration.

  6. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01W33I

      Engage the guide and 2 claws to install the No. 1 air duct sub-assembly as shown in the illustration.

  7. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A01W2XD

      Engage the 2 guides and 2 claws to install the No. 6 heater to register duct assembly as shown in the illustration.

  8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Engage each clamp to install the air conditioning harness assembly.

    2. Connect each connector.

  9. INSTALL BLOWER ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  10. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

      A01W3B0E04
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

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

  11. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    Note


    • Be sure to support the air conditioning unit assembly when installing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.

    • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. Engage the 3 guides and temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

      A01W5DF

    2. Install the instrument panel reinforcement assembly with the 3 bolts <A> and 2 new bolts <B> in the order shown in the illustration.

      A01W577E04
      Text in Illustration
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

    3. Install the bolt <C>.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    4. Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    5. Pass the drain cooler hose through the vehicle securely.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

    6. A01W0C9E07

      Install the 2 bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

    7. Install the 2 hole plugs.

    8. for LHD:


      1. Engage each clamp.

      2. Connect the connector.

      3. Connect the 4 earth wires with the 4 bolts.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      4. Connect the protector with the nut.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      5. Connect the connector holder with the 2 nuts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    9. for RHD:


      1. Engage each clamp.

      2. Connect the connector.

      3. Connect the 4 earth wires with the 4 bolts.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      4. Connect the connector holder with the 2 nuts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    10. Engage the claw to connect the airbag connector as shown in the illustration.

      A01W20T
    11. A01W1I1E09
      Text in Illustration
      *a Retainer

      Engage the 2 claws to lock the retainer as shown in the illustration.

    12. w/ PTC Heater:


      1. Connect the connector.

      2. Install the bolt.

        Torque:
        20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      3. for U660E Automatic Transmission / Transaxle:


        1. Install the shift lever support Click here.

        2. Install the lower shift lever assembly Click here.

      4. for U760E Automatic Transmission / Transaxle:


        1. Install the shift lever support Click here.

        2. Install the lower shift lever assembly Click here.

      5. for U761E Automatic Transmission / Transaxle:


        1. Install the shift lever support Click here

        2. Install the lower shift lever assembly Click here

    13. Engage each clamp.

      A01W4QYE01
      Text in Illustration
      *1 Airbag Sensor Assembly - -

    14. Connect each connector.

    15. Connect the connector to the airbag sensor assembly as shown in the illustration.

      Note

      When connecting any airbag connector, take care not to damage the airbag wire harness.

    16. A01W4KZ

      Engage the 3 claws to close the 3 clamps as shown in the illustration.

    17. w/ Telematics Transceiver:


      1. Engage each clamp.

    18. Engage each clamp.

  12. INSTALL INSTRUMENT PANEL SAFETY PAD CAP


    1. A01W3L7E07
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Install 5 new instrument panel safety pad caps.

  13. INSTALL NO. 1 HEATER TO REGISTER DUCT


    1. Install the No. 1 heater to register duct with the 3 clips.

    2. Engage the clamp.

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


    1. Install the No. 2 instrument panel brace sub-assembly with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Install the screw.

    3. Engage each clamp.

    4. Connect the connector.

    5. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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


    1. Install the No. 1 instrument panel brace sub-assembly with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Install the screw.

    3. Engage the clamp.

    4. Connect the connector.

  16. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR


    1. Connect the cooler thermistor hose and connector to install the cooler (room temp. sensor) thermistor.

  17. INSTALL NO. 1 CONSOLE BOX DUCT


    1. Install the No. 1 console box duct with the clip.

  18. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET (w/ PTC Heater)

    for U660E Automatic Transmission / Transaxle: Click here

    for U760E Automatic Transmission / Transaxle: Click here

    for U761E Automatic Transmission / Transaxle: Click here

  19. INSTALL FLOOR CARPET BRACKET LH


    1. Engage the 2 guides.

    2. Install the floor carpet bracket LH with the 2 clips.

  20. INSTALL REAR NO. 2 AIR DUCT


    1. Engage the 2 claws to install the rear No. 2 air duct.

  21. INSTALL REAR AIR DUCT GUIDE LH


    1. Engage the 4 claws to install the rear air duct guide LH.

    2. A01W4G4

      Engage the guide to install the floor carpet to the original position as shown in the illustration.

  22. INSTALL FLOOR CARPET BRACKET RH


    1. Engage the 2 guides.

    2. Install the floor carpet bracket RH with the 2 clips.

  23. INSTALL REAR NO. 1 AIR DUCT


    1. Engage the 2 claws to install the rear No. 1 air duct.

  24. INSTALL REAR AIR DUCT GUIDE RH


    1. Engage the 4 claws to install the rear air duct guide RH.

    2. A01W5PE

      Engage the guide to install the floor carpet to the original position as shown in the illustration.

  25. INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. A01W1ZS

      Engage the guide and claw to install the front floor caution plate cover.

  26. INSTALL FLOOR CARPET HOOK


    1. Engage the 6 clamps to install the 6 floor carpet hooks.

    2. Engage the 6 guides.

  27. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  28. INSTALL ECU INTEGRATION BOX RH

    for LHD: Click here

    for RHD: Click here

  29. INSTALL WIRING HARNESS CLAMP BRACKET (for RHD)


    1. Engage the claw.

    2. Install the wiring harness clamp bracket with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

    Click here

  31. INSTALL ENGINE STOP AND START ECU ASSEMBLY (w/ Stop and Start System)

    Click here

  32. INSTALL DRIVING SUPPORT ECU ASSEMBLY (w/ Pre-crash Safety System)

    Click here

  33. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

    Click here

  34. INSTALL STEERING POST ASSEMBLY

    Click here

  35. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  36. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET

    Click here

  37. INSTALL AUDIO AMPLIFIER COVER

    Click here

  38. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  39. INSTALL TELEMATICS TRANSCEIVER (w/ Telematics Transceiver except G-BOOK)

    Click here

  40. INSTALL TELEMATICS TRANSCEIVER WITH MAYDAY BATTERY (w/ Telematics Transceiver for G-BOOK)

    Click here

  41. INSTALL AUDIO AMPLIFIER COVER (w/ Telematics Transceiver)

    Click here

  42. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  43. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the air conditioning tube and accessory assembly.

    2. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube and accessory assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.

    4. Install the air conditioning tube and accessory assembly.

  44. 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 8 or equivalent

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

    4. Connect the suction pipe sub-assembly.

    5. A01W3CO

      Rotate the hook connector in the direction indicated by the arrow in the illustration.

    6. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  45. CONNECT HEATER INLET WATER HOSE


    1. A01VZNPE04
      Text in Illustration
      *a View A
      *b

      for 2GR-FE:

      Marking (Brown)

      for 2AR-FE:

      Marking (Yellow)

      for 6AR-FSE:

      Marking (Purple)
      *c Clip installation angle (75 to 105°)

      Connect the heater inlet water hose with the marking facing up and engage the clip within the area shown in the illustration.

      Note

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

  46. CONNECT HEATER OUTLET WATER HOSE


    1. A01W1USE04
      Text in Illustration
      *a View A
      *b

      for 2GR-FE without ATF Warmer:

      Marking (Pink)

      for 2GR-FE with ATF Warmer:

      Marking (Green)

      for 2AR-FE:

      Marking (Red)

      for 6AR-FSE:

      Marking (Purple)
      *c Clip installation angle (30 to 60°)

      Connect the heater outlet water hose with the marking facing up and engage the clip within the area shown in the illustration.

      Note

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

  47. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  48. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  49. ADD ENGINE COOLANT (for 2AR-FE)

    Click here

  50. ADD ENGINE COOLANT (for 2GR-FE)

    Click here

  51. ADD ENGINE COOLANT (for 6AR-FSE)

    Click here

  52. INSPECT FOR COOLANT LEAK (for 2AR-FE)

    Click here

  53. INSPECT FOR COOLANT LEAK (for 2GR-FE)

    Click here

  54. INSPECT FOR COOLANT LEAK (for 6AR-FSE)

    Click here

  55. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  56. WARM UP ENGINE

    Click here

  57. INSPECT FOR REFRIGERANT LEAK

    Click here

  58. INITIALIZE SERVO MOTOR

    Click here

  59. INSPECT SHIFT LEVER POSITION (w/ PTC Heater)

    for U660E Automatic Transmission / Transaxle: Click here

    for U760E Automatic Transmission / Transaxle: Click here

    for U761E Automatic Transmission / Transaxle: Click here