AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 AIR DUCT


    1. Engage the 3 claws to install the No. 2 air duct.

  2. INSTALL NO. 1 AIR DUCT


    1. Engage the 3 claws to install the No. 1 air duct.

  3. INSTALL COOLER AIR HOSE (for Automatic Air Conditioning System)


    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. B0047I2

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

    2. Tighten the screw.

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


    1. B0046FK

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

    2. Tighten the screw.

  7. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for LHD)


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

  8. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for RHD)


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

  9. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY


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

      Note

      To prevent damage to the installation bracket for the air conditioning unit assembly, 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.

      B0045IP

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


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

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


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

  13. INSTALL AIR CONDITIONER UNIT ASSEMBLY (for LHD)


    1. Install the air duct with the 2 bolts.

      B00458QE02
      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:
      Bolt
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  14. INSTALL AIR CONDITIONER UNIT ASSEMBLY (for RHD)


    1. Install the air duct with the 2 bolts.

      B0047JFE02
      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:
      Bolt
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  15. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. Connect the connectors to 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 to connect the instrument panel wire.

      2. Connect the 2 connectors.

    4. for Manual Air Conditioning System:


      1. Engage the 3 clamps to disconnect the instrument panel wire.

      2. Connect the 3 connectors.

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

    10. Tighten the screw.

    11. Connect the connectors.

    12. B0045VF

      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 to 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 to connect the instrument panel wire.

      2. Connect the 2 connectors.

    4. for Manual Air Conditioning System:


      1. Engage the 5 clamps to disconnect the instrument panel wire.

      2. Connect the 3 connectors.

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

    10. Tighten the screw.

    11. Connect the connectors.

    12. B0045UD

      Connect the 2 clamps.

  17. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


    1. B0045W3E02

      Connect the back side connectors to install the instrument panel junction block assembly in the order as shown in the illustration.

      Note

      Securely connect the connector.

    2. B0046GZ

      Install the instrument panel junction block assembly with the bolt.

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

    3. 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. B0047QDC01
      *a UP Mark
      *b 60°

      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 to install the rear No. 3 air duct.

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


    1. Install the 2 claws to install the rear No. 4 air duct.

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


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

    2. B0045QR

      Return the floor carpet.

  22. INSTALL DEFROSTER NOZZLE ASSEMBLY


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

    2. Engage the clamps to 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 to install the heater to register duct assembly.

    2. Engage the clamp to connect the wire harness.

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


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

  26. INSTALL STEERING COLUMN ASSEMBLY (for LHD)

    Click here

  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. B00460FC01
      *a View A
      *b White Paint Mark
      *c 60°

      Connect the water hose sub-assembly 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. B0047NVC01
      *a View A
      *b White Paint Mark
      *c 90°

      Connect the water hose sub-assembly 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. B0047A0C01
      *a View A
      *b White Paint Mark
      *c 120°

      Connect the water hose sub-assembly 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. B0047KIC01
      *a View A
      *b White Paint Mark

      Connect the water hose sub-assembly 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 to a new O-ring and the connecting part of the liquid tube sub-assembly A.

      Compressor oil
      for HFC-134a (R134a)
      ND-OIL 8 or equivalent
      for HFO-1234yf (R1234yf)
      ND-OIL 12 or equivalent

    3. Install the O-ring onto the liquid tube sub-assembly A.

    4. Connect the liquid tube to the unit.

  35. CONNECT SUCTION TUBE SUB-ASSEMBLY B


    1. Remove the vinyl tape from suction tube sub-assembly B and the connecting portion of the unit.

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

      Compressor oil
      for HFC-134a (R134a)
      ND-OIL 8 or equivalent
      for HFO-1234yf (R1234yf)
      ND-OIL 12 or equivalent

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

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

    5. B0047K8

      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. B0046OSC02
      *1 Vacuum Hose
      *a View A
      *b View B
      *c 30°

      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

    Click here

  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

    Click here

  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)

    Click here

  44. ADD ENGINE COOLANT (for 2NR-FKE)

    Click here

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

    Click here

  46. ADD ENGINE COOLANT (for 2ZR-FE)

    Click here

  47. BLEED AIR FROM FUEL SYSTEM

    Click here

  48. CHARGE REFRIGERANT


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

    Click here

  50. INSPECT FOR COOLANT LEAK (for 2NR-FKE)

    Click here

  51. INSPECT COOLANT LEAK (for 1ND-TV)

    Click here

  52. INSPECT COOLANT LEAK (for 2ZR-FE)

    Click here

  53. INSPECT FOR FUEL LEAK

    Click here

  54. WARM UP ENGINE


  55. INSPECT FOR REFRIGERANT LEAK