AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 AIR DUCT


    1. Engage the 3 claws and install the air duct.

  2. INSTALL NO. 1 AIR DUCT


    1. Engage the 3 claws and install the air duct.

  3. INSTALL COOLER AIR HOSE


    1. Install the cooler air hose.

  4. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY


    1. Install the air conditioning radiator with the 3 screws.

  5. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (for Automatic Air Conditioning System)


    1. A01VHP3

      Engage the claw and install the air conditioning amplifier as shown in the illustration.

    2. Tighten the screw.

  6. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (for Manual Air Conditioning System)


    1. A01VK5J

      Engage the claw and install the air conditioning amplifier as shown in the illustration.

    2. Tighten the screw.

  7. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for LHD)


    1. Connect the connectors and engage the clamps, then install the air conditioning harness.

  8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for RHD)


    1. Connect the connectors and engage the clamps, then install the air conditioning harness.

  9. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY


    1. Temporarily tighten the air conditioning unit with the 3 bolts and nut.

      Note

      To prevent damage to the installation bracket for the air conditioning unit, be sure to support the air conditioning unit in place.

  10. INSTALL INSTRUMENT PANEL REINFORCEMENT


    1. Install the instrument panel reinforcement with the 8 bolts.

      A01VF5Z

  11. INSTALL REAR NO. 1 AIR DUCT (for Cold Area Specification Vehicles)


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

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


    1. Install the instrument panel brace with the 2 bolts, nut and screw.

  13. INSTALL AIR CONDITIONER UNIT ASSEMBLY (for LHD)


    1. Install the air duct with the 2 bolts.

      A01VF26E02
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    2. Install the bolt, nut and 4 screws in the order shown in the illustration.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      for bolt
      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      for nut
      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      for screw 1, 2, 3

  14. INSTALL AIR CONDITIONER UNIT ASSEMBLY (for RHD)


    1. Install the air duct with the 2 bolts.

      A01VGI3E02
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    2. Install the bolt, nut and 4 screws in the order shown in the illustration.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      for bolt
      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      for nut
      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      for screw 1, 2, 3

  15. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. Connect the connectors and engage the clamps, then install the instrument panel wire.

    2. Install the ground wire with the bolts.

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

    3. for Automatic Air Conditioning System:


      1. Engage the clamp and connect the instrument panel wire.

      2. Connect the 2 connectors.

    4. for Manual Air Conditioning System:


      1. Engage the 3 clamps and install the instrument panel wire.

      2. Connect the 3 connectors.

    5. Connect the 3 clamps and install the connector holders.

    6. Tighten the bolt.

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

    7. Connect the connectors.

    8. Install the connector holder with the screw.

    9. Connect the 2 clamps and install the connector holders.

    10. Tighten the screw.

    11. Connect the connectors.

    12. A01VJ0V

      Connect the 2 clamps.

    13. for Cold Area Specification Vehicles:


      1. Install the ground wire with the bolt.

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

  16. INSTALL INSTRUMENT PANEL WIRE (for RHD)


    1. Connect the connectors and engage the clamps, then install the instrument panel wire.

    2. Install the ground wire with the bolts.

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

    3. for Automatic Air Conditioning System:


      1. Engage the 3 clamps and connect the instrument panel wire.

      2. Connect the 2 connectors.

    4. for Manual Air Conditioning System:


      1. Engage the 5 clamps and install the instrument panel wire.

      2. Connect the 3 connectors.

    5. Connect the 3 clamps and install the connector holders.

    6. Tighten the bolt.

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

    7. Connect the connectors.

    8. Install the connector holder with the screw.

    9. Connect the 2 clamps and install the connector holders.

    10. Tighten the screw.

    11. Connect the connectors.

    12. A01VES9

      Connect the 2 clamps.

  17. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


    1. A01VEU3E02

      Connect the back side connectors and install the instrument panel junction block as shown in the illustration.

      Note

      Securely connect the connector.

    2. Install the instrument panel junction block with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    3. A01VKSE

      Connect the front side connectors as shown in the illustration.

      Note

      Securely connect the connector.

    4. Engage the clamps.

  18. CONNECT DRAIN COOLER HOSE


    1. A01VHIHE02
      Text in Illustration
      *a UP Mark

      Install the drain cooler hose as shown in the illustration.

      Note


      • Install the drain hose with its UP mark facing upward, within the 60 degree range shown in the illustration.

      • Install the drain hose without twisting it.

  19. INSTALL REAR NO. 3 AIR DUCT (for Cold Area Specification Vehicles)


    1. Install the 2 claws and install the air duct.

  20. INSTALL REAR NO. 4 AIR DUCT (for Cold Area Specification Vehicles)


    1. Install the 2 claws and install the air duct.

  21. INSTALL REAR NO. 2 AIR DUCT (for Cold Area Specification Vehicles)


    1. Install the 2 claws and install the air duct.

    2. A01VLB7

      Return the floor carpet.

  22. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. Engage the 2 claws and 3 guides, then install the defroster nozzle.

    2. Engage the clamps and connect the connectors, then connect the wire harness.

  23. INSTALL NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System)

    Click here

  24. INSTALL HEATER TO REGISTER DUCT ASSEMBLY (w/ Navigation System)


    1. Engage the 3 claws and install the heater to register duct.

    2. Engage the clamp and connect the wire harness.

  25. INSTALL HEATER TO REGISTER DUCT ASSEMBLY (w/o Navigation System)


    1. Engage the 3 claws and install the heater to register duct.

  26. INSTALL STEERING COLUMN ASSEMBLY (for LHD)

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  27. INSTALL STEERING COLUMN ASSEMBLY (for RHD)

    Click here

  28. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  29. CONNECT WATER HOSE SUB-ASSEMBLY (for TMC Made)


    1. A01VEKOE02
      Text in Illustration
      *a View A
      *b White Paint Mark

      Connect the water hose onto the air conditioning unit.

      Tech Tips

      Perform the installation with the hose clip and mark at the correct angle.

  30. CONNECT WATER HOSE SUB-ASSEMBLY B (for TMC Made)


    1. A01VH1DE02
      Text in Illustration
      *a View A
      *b Purple Paint Mark

      Connect the water hose onto the air conditioning unit.

      Tech Tips

      Perform the installation with the hose clip and mark at the correct angle.

  31. CONNECT WATER HOSE SUB-ASSEMBLY (for TMMF Made)


    1. A01VG90E02
      Text in Illustration
      *a View A
      *b White Paint Mark

      Connect the water hose onto the air conditioning unit.

      Tech Tips

      Perform the installation with the hose clip and mark at the correct angle.

  32. CONNECT WATER HOSE SUB-ASSEMBLY B (for TMMF Made)


    1. A01VINWE02
      Text in Illustration
      *a View A
      *b Purple Paint Mark

      Connect the water hose onto the air conditioning unit.

      Tech Tips

      Perform the installation with the hose clip and mark at the correct angle.

  33. INSTALL FUEL FILTER ASSEMBLY WITH SUPPORT (for 1ND-TV)

    Click here

  34. CONNECT LIQUID TUBE SUB-ASSEMBLY A


    1. Remove the vinyl tape from liquid tube and the connecting portion of the unit.

    2. Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the liquid tube.

      Compressor oil
      ND-OIL8 or equivalent

    3. Install the O-ring onto the liquid tube.

    4. Connect the liquid tube to the unit.

  35. CONNECT SUCTION TUBE SUB-ASSEMBLY B


    1. Remove the vinyl tape from suction tube and the connecting portion of the unit.

    2. Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the suction tube.

      Compressor oil
      ND-OIL8 or equivalent

    3. Install the O-ring onto the suction tube.

    4. Securely connect the suction tube to the air conditioning unit.

    5. A01VKI2

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

    6. Insert the pipe joints securely into the fitting holes and tighten the bolt.

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

  36. INSTALL BOOSTER VACUUM TUBE (for 1ND-TV)


    1. A01VHGOE02
      Text in Illustration
      *a View A
      *b View B

      Install the booster vacuum tube with the 2 bolts.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    2. Connect the 2 hoses onto the vacuum pump and brake booster.

      Tech Tips

      Perform the installation with the hose clip at the correct angle.

  37. INSTALL OUTER COWL TOP PANEL

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  38. INSTALL INNER COWL TOP TO COWL BRACE

    Click here

  39. INSTALL FRONT AIR SHUTTER SEAL RH

    Click here

  40. INSTALL FRONT NO. 1 VENTILATOR SEAL

    Click here

  41. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  43. ADD ENGINE COOLANT (for 1KR-FE)

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  44. ADD ENGINE COOLANT (for 1NR-FE)

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  45. ADD ENGINE COOLANT (for 1ND-TV)

    Click here

  46. BLEED AIR FROM FUEL SYSTEM

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  47. CHARGE REFRIGERANT

    Click here

  48. INSPECT FOR COOLANT LEAK (for 1KR-FE)

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  49. INSPECT FOR COOLANT LEAK (for 1NR-FE)

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  50. INSPECT FOR COOLANT LEAK (for 1ND-TV)

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  51. INSPECT FOR FUEL LEAK

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  52. WARM UP ENGINE

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  53. INSPECT FOR REFRIGERANT LEAK

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