AIR CONDITIONING UNIT (for Front Side) INSTALLATION

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Install the air conditioning unit with the nut.

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

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement with the No. 1 instrument panel spacer.

      A01GHV5E01
      Text in Illustration
      *1 Collar *2 "TORX" Bolt
      *3 No. 1 Instrument Panel Spacer - -

    2. Passenger side:

      Using a 12 mm hexagon wrench, tighten the 3 collars.

    3. Using a T40 "TORX" socket, install the 6 "TORX" bolts.

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

    4. Install the 6 instrument panel safety pad caps.

    5. Install the 9 bolts and 2 screws.

      A01GIXHE01
      Torque:
      for Bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for Bolt B
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    6. Connect the ground wires and install the junction block with the bolts and nuts.

      Torque:
      for Nut C
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for Bolt D
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    7. Attach the clamps and connectors and install the wire harness.

  3. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  4. CONNECT COOLER UNIT DRAIN HOSE


    1. A01GISP

      Connect the 2 cooler unit drain hoses as shown in the illustration.

  5. INSTALL STEERING COLUMN ASSEMBLY

    w/o VGRS: Click here

    for 2WD with VGRS: Click here

    for AWD with VGRS; Click here

  6. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. Attach the 2 claws to install the No. 1 air duct sub-assembly.

    2. Install the bolt.

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

  7. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. Attach the 2 claws to install the No. 2 air duct sub-assembly.

    2. Install the screw.

  8. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  9. CONNECT HEATER WATER OUTLET HOSE


    1. A01GKG2E01
      Text in Illustration
      *1 Paint Mark
      *a 30° to 60°
      *b 75° to 105°

      Connect the heater water outlet hose and attach the clip.

      Tech Tips

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

  10. CONNECT HEATER WATER INLET HOSE

    Tech Tips

    Use the same procedure described for the water outlet hose.

  11. CONNECT COOLER REFRIGERANT LIQUID PIPE A


    1. Remove the attached vinyl tape from the pipe.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe A.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the cooler refrigerant liquid pipe A.

    4. Connect the cooler refrigerant liquid pipe A.

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

    6. Install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

  12. CONNECT SUCTION TUBE SUB-ASSEMBLY B


    1. Remove the attached vinyl tape from the tube.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction tube sub-assembly B.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction tube sub-assembly B.

    4. A01GNJRE02

      Connect the suction tube sub-assembly B.

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

    6. Install the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  14. INSTALL COWL TOP VENTILATOR LOUVER


    1. A01GM4S

      for LHD:

      Install the 6 clips and cowl top ventilator louver RH.

      Note

      If the cowl top ventilator louver RH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver RH is installed properly.

    2. A01GI9P

      for RHD:

      Install the 6 clips and cowl top ventilator louver LH.

      Note

      If the cowl top ventilator louver LH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver LH is installed properly.

  15. ADD ENGINE COOLANT

    for 1UR-FE: Click here

    for 1UR-FSE: Click here

  16. ADD COMPRESSOR OIL


    1. When performing work on air conditioning parts, follow the oil guidelines below in order to protect the cooler compressor.

      Part and Condition Oil Level (cc) Work Procedure
      Compressor replacement -100 to -120 Drain oil from new compressor
      Condenser replacement 35 to 55 Fill oil into replacement part
      Evaporator replacement 40 to 60
      A/C pipe replacement High pressure 5 to 25
      Low pressure
      When discharging refrigerant gas quickly 30 to 50 While applying vacuum, use manifold gauge to fill oil from low pressure side valve

  17. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard
      Destination Air Conditioning Type Refrigerant Charging Amount
      except G.C.C Countries w/o Rear Cooler 550 +/-50 g (19.4 +/-1.8 oz.)
      w/ Rear Cooler 700 +/-30 g (24.7 +/-1.1 oz.)
      G.C.C Countries w/o Rear Cooler 750 +/-30 g (26.5 +/-1.1 oz.)
      w/ Rear Cooler 1000 +/-50 g (35.3 +/-1.8 oz.)
      A01GLM7E02
      Text in Illustration
      *a Amount to be charged *b Charge 100 g (3.53 oz)
      *c Mean value in proper range *d Point where bubbles disappear
      *e Overcharged *f Pressure
      *g Sub-cool system *h Refrigerant amount

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  18. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.

  19. INSPECT FOR ENGINE COOLANT LEAK

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before each inspection, turn the A/C switch OFF.


    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

  20. CHECK FOR LEAKAGE OF REFRIGERANT


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        Tech Tips

        When compressor is off:

        approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A01GLRYE01
      Text in Illustration
      *1 Halogen Leak Detector
      *a Check for Leakage

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

  21. CHECK SRS WARNING LIGHT

    Click here