AIR CONDITIONING UNIT(for Automatic 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

    A004S2Q

    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.

      A004QSQE16
      Text in Illustration
      *1 w/ PTC Heater *3 9.8 N*m (100 kgf*cm, 87 in.*lbf)
      *2 24 N*m (245 kgf*cm, 18 ft.*lbf) *4 for Manual Transaxle

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

    A004R02E02

    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 4 clamps.

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

    A004NNXE03

    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)

    A004THI

    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

    A004RHL

    1. Install the brace with the 2 bolts.

  8. INSTALL AIR DUCT ASSEMBLY

    A004TGI

    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. A004QY8

      Attach the 4 claws to install the defroster nozzle assembly.

  10. INSTALL COOLER (SOLAR SENSOR) THERMISTOR

    Click here

  11. INSTALL STEERING COLUMN ASSEMBLY


    1. Install the steering column Click here.

  12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

    A004NG1

    1. Attach the 2 claws to install the duct.

  13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

    A004SFV

    1. Attach the 2 claws to install the duct.

  14. INSTALL REAR NO. 1 AIR DUCT

    A004QUM

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

  15. INSTALL REAR NO. 2 AIR DUCT

    A004SQ5

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

    2. A004NGJ

      Install the floor carpet with the clip.

  16. INSTALL REAR NO. 3 AIR DUCT

    A004Q89

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

    2. A004O4E

      Install the floor carpet with the clip.

  17. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the lower instrument panel Click here.

  18. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the upper instrument panel Click here.

  19. CONNECT HEATER WATER INLET HOSE

    A004NVNE03
    Text in Illustration
    *a Paint Mark (White)

    1. Connect the heater water inlet hose.

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

  20. CONNECT HEATER WATER OUTLET HOSE

    A004OFOE01
    Text in Illustration
    *a Paint Mark (White)

    1. Connect the heater water outlet hose.

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

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


    1. A004QTM

      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 }

  22. 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. A004QMC

      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 }

  23. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  24. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)

    Click here

  25. INSTALL FRONT WIPER MOTOR AND BRACKET


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

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  27. CHECK SRS WARNING LIGHT


    1. Check the SRS warning light Click here.

  28. ADD ENGINE COOLANT


    1. for 1WW:

      Add engine coolant Click here.

    2. for 2WW:

      Add engine coolant Click here.

  29. CHARGE REFRIGERANT


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  30. WARM UP ENGINE


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  31. INSPECT FOR COOLANT LEAK


    1. for 1WW:

      Inspect for engine coolant leak Click here.

    2. for 2WW:

      Inspect for engine coolant leak Click here.

  32. CHECK FOR REFRIGERANT GAS LEAK


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  33. INSTALL NO. 1 ENGINE COVER

    Click here

  34. INSTALL FRONT LOWER BUMPER ABSORBER

    Click here

  35. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  36. INSTALL NO. 1 ENGINE UNDER COVER

    Click here