AIR CONDITIONING UNIT (for Rear Side) INSTALLATION

Tech Tips

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


  1. INSTALL REAR COOLING UNIT ASSEMBLY


    1. A01GJILE02
      Text in Illustration
      *1 Marking

      Install the rear cooling unit assembly with the 4 bolts.

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

      Note

      When installing the drain hose, make sure the marking is as shown in the illustration.

    2. Connect the clamp and connector.

  2. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the tube.

      Compressor oil
      ND-OIL 8 or equivalent

    2. Install the 2 O-rings to the air conditioning tube and accessory assembly.

    3. Connect the air conditioning tube and accessory with the 2 bolts.

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

    4. Attach the 3 claws to install the cover.

  3. INSTALL NO. 2 COOLER AIR DUCT


    1. Attach the 3 claws to install the No. 2 cooler air duct.

  4. INSTALL NO. 1 COOLER AIR DUCT


    1. Attach the 2 claws to install the No. 1 cooler air duct.

  5. INSTALL REAR NO. 4 AIR DUCT


    1. Attach the 4 claws to install the rear No. 4 air duct.

  6. INSTALL REAR NO. 5 AIR DUCT


    1. Attach the 4 claws to install the rear No. 5 air duct.

  7. INSTALL ROOF SIDE NO. 2 AIR DUCT LH


    1. Attach the 2 claws to install the roof side No. 2 air duct LH.

    2. Install the clip.

  8. INSTALL ROOF SIDE NO. 2 AIR DUCT RH


    1. Attach the 2 claws to install the roof side No. 2 air duct RH.

    2. Install the clip.

  9. INSTALL LUGGAGE COMPARTMENT TRIM COVER ASSEMBLY LH


    1. A01GJ4PE02
      Text in Illustration
      *A w/o Rear Cooler
      *B w/ Rear Cooler

      Install the luggage compartment trim cover assembly LH with the claw and 2 clips.

  10. INSTALL LUGGAGE COMPARTMENT TRIM COVER ASSEMBLY RH


    1. A01GMS7E01
      Text in Illustration
      *A w/o Rear Cooler
      *B w/ Rear Cooler

      Install the luggage compartment trim cover assembly RH with the claw and 2 clips.

  11. INSTALL REAR FLOOR FINISH PLATE


    1. A01GHU1

      Attach the 4 clips to install the rear floor finish plate.

    2. Install the 3 clips.

  12. INSTALL FRONT LUGGAGE COMPARTMENT TRIM COVER


    1. w/o Rear Cooler:


      1. A01GJSC

        Install the front luggage compartment trim cover with the 4 claws and 3 clips.

      2. Attach the 3 clips.

      3. Install the 2 rope hooks.

    2. w/ Rear Cooler:


      1. A01GI60

        Install the front luggage compartment trim cover with the 4 claws and 5 clips.

      2. Install the 2 rope hooks.

  13. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY


    1. A01GJYH

      Connect the connector.

    2. Attach the 2 claws to install the No. 1 luggage compartment light assembly.

  14. INSTALL DECK TRIM SIDE BOARD LH

    A01GJT4E02
    Text in Illustration
    *A w/ Spare Tire
    *B w/o Spare Tire

    1. w/ Spear Tire:


      1. Install the deck trim side board LH with the clip.

    2. w/o Spear Tire:


      1. Attach the clip to install the deck trim side board LH.

  15. INSTALL DECK TRIM SIDE BOARD RH

    A01GL8HE02
    Text in Illustration
    *A w/ Spare Tire
    *B w/o Spare Tire

    1. w/ Spear Tire:


      1. Install the deck trim side board RH with the clip.

    2. w/o Spear Tire:


      1. Attach the clip to install the deck trim side board RH.

  16. INSTALL ROPE HOOK


    1. A01GJF0

      Install the 2 rope hooks.

  17. INSTALL ROPE HOOK ASSEMBLY


    1. A01GMHF

      Install the 4 rope hook assemblies with the 4 bolts.

  18. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

    A01GIID

  19. INSTALL NO. 1 COOLER COVER


    1. A01GI3S

      Attach the 2 clips to install the No. 1 cooler cover.

  20. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY


    1. w/ Rear Cooler:

      Connect the solar sensor connector.

    2. except 4-Passenger with Ottoman:

      Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly.

    3. for 4-Passenger with Ottoman:

      Pass the 2 rear seat belt floor anchors through the package tray trim panel assembly.

    4. Insert the rear part of the package tray trim panel assembly into the rear sunshade assembly.

    5. Attach the 2 clips to install the package tray trim panel assembly.

    6. except 4-Passenger with Ottoman:

      Attach the 4 claws to install the 3 belt guides.

    7. for 4-Passenger with Ottoman:

      Attach the 4 claws to install the 2 belt guides.

  21. INSTALL INNER ROOF SIDE GARNISH LH

    A01GK2ME06
    Text in Illustration
    *1 Clip A

    1. Install a new clip A to the inner roof side garnish LH.

    2. Attach the 2 claws and 5 clips to install the inner roof side garnish LH.

  22. INSTALL INNER ROOF SIDE GARNISH RH

    Tech Tips

    Use the same procedure described for the LH side.

  23. INSTALL REAR SEAT SIDE GARNISH LH


    1. Attach the 6 claws to install the rear seat side garnish LH.

  24. INSTALL REAR SEAT SIDE GARNISH RH

    Tech Tips

    Use the same procedure described for the LH side.

  25. INSTALL REAR DOOR SCUFF PLATE LH

    A01GNST

    1. Attach the 3 clips.

    2. Attach the 7 claws to install the rear door scuff plate LH.

  26. INSTALL REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  27. INSTALL REAR SEAT ASSEMBLY

    for Power Seat: Click here

    for Ottoman: Click here

  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  29. INSTALL COWL TOP VENTILATOR LOUVER RH


    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.

  30. 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

  31. 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.

  32. 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.

  33. 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.

  34. CHECK SRS WARNING LIGHT

    Click here