AIR CONDITIONING UNIT(for Manual Air Conditioning System) INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for LHD and RHD vehicles.

  • The procedure listed below is for LHD vehicles.

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

PROCEDURE


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY

    A0053US

    1. Install the air conditioning unit with the nut and bolt.

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

    2. Connect the drain cooler hose.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement.


      1. Install the instrument panel reinforcement with the bolts and screws.

    2. Attach the clamps and connectors to attach the wire harness.

      A0057VFE13
      Text in Illustration
      *1 for Manual Transaxle *2 w/ PTC Heater
      *3 24 N*m (245 kgf*cm, 18 ft.*lbf) *4 9.8 N*m (100 kgf*cm, 87 in.*lbf)

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

    A0054AOE02

    1. Install the brace with the 2 bolts and nut.

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

    2. Attach the clamps.

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

    A0052UYE01

    1. Install the brace with the 2 bolts and nut.

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

    2. Attach the clamp.

  5. INSTALL MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY)

    A0053VU

    1. Install the main body ECU with the 2 bolts.

    2. Connect the 3 connectors.

  6. INSTALL POWER STEERING ECU ASSEMBLY


    1. for LHD:

      Install the power steering ECU assembly Click here.

    2. for RHD:

      Install the power steering ECU assembly Click here.

  7. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE

    A0054JW

    1. Install the brace with the 2 bolts.

  8. INSTALL AIR DUCT ASSEMBLY

    A0058LO

    1. Install the duct with the 2 nuts.

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

  9. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. A0053YI

      Attach the 4 claws to install the defroster nozzle assembly.

  10. INSTALL STEERING COLUMN ASSEMBLY


    1. Install the steering column Click here.

  11. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

    A0055ZR

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

  12. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

    A0052JZ

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

  13. INSTALL REAR NO. 1 AIR DUCT

    A0057S2

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

  14. INSTALL REAR NO. 2 AIR DUCT

    A0056HO

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

    2. A0054UY

      Install the floor carpet with the clip.

  15. INSTALL REAR NO. 3 AIR DUCT

    A0053J2

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

    2. A0056JI

      Install the floor carpet with the clip.

  16. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the lower instrument panel Click here.

  17. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the upper instrument panel Click here.

  18. CONNECT HEATER WATER INLET HOSE

    A0054PJ

    1. Connect the heater water inlet hose.

    2. Using pliers, grip the claws of the clip and slide the clip.

  19. CONNECT HEATER WATER OUTLET HOSE

    A0053CT

    1. Connect the heater water outlet hose.

    2. Using pliers, grip the claws of the clip and slide the clip.

  20. CONNECT AIR CONDITIONING TUBE ASSEMBLY (for HFC-134a(R134a))


    1. A00562O

      Remove the attached vinyl tape from the tubes.

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the air conditioning tube assembly.

    5. Attach the plate as shown in the illustration and install the bolt.

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

  21. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (for HFO-1234yf(R1234yf))


    1. Remove the attached vinyl tape from the pipe and air conditioning unit.

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

      Compressor oil
      ND-OIL 12 or equivalent

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

    4. A0055SJ

      Securely connect the air conditioning tube and accessory to the air conditioning unit.

    5. Move the hook connector in the direction indicated by the arrow in the illustration and install the bolt.

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

  22. INSTALL COWL TOP OUTER PANEL

    Click here

  23. INSTALL FRONT WIPER MOTOR AND BRACKET


    1. Install the front wiper motor and bracket Click here.

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  25. CHECK SRS WARNING LIGHT


    1. Check the SRS warning light Click here.

  26. ADD ENGINE COOLANT


    1. for 1ZR-FAE:

      Add engine coolant Click here.

    2. for 2ZR-FAE:

      Add engine coolant Click here.

    3. for 3ZR-FAE:

      Add engine coolant Click here.

  27. CHARGE REFRIGERANT


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  28. WARM UP ENGINE


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  29. INSPECT FOR COOLANT LEAK


    1. for 1ZR-FAE:

      Inspect for engine coolant leak Click here.

    2. for 2ZR-FAE:

      Inspect for engine coolant leak Click here.

    3. for 3ZR-FAE:

      Inspect for engine coolant leak Click here.

  30. CHECK FOR REFRIGERANT GAS LEAK


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  31. INSTALL NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)

    Click here

  32. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  33. INSTALL FRONT LOWER BUMPER ABSORBER

    Click here

  34. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  35. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here