AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY

    Note


    • Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause brackets of the air conditioning unit assembly to break.

    • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent electrical components from being damaged.


    1. B001MQO

      Temporarily tighten the air conditioning unit assembly with the bolt and nut.

    2. Connect the drain cooler hose.

      Note

      Connect the drain cooler hose firmly to prevent water leaks.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT


    1. Install the instrument panel reinforcement assembly with the 5 bolts <A>.

    2. Install the air conditioning unit assembly with the 3 bolts <B>.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

      B001LSTN01

    3. for LHD:


      1. Install the brake pedal support assembly to the instrument panel reinforcement with the bolt.

        Torque:
        24 N*m  { 241 kgf*cm, 17 ft.*lbf }

      2. Connect the center airbag sensor connectors to the center airbag sensor assembly as shown in the illustration.

        Note

        When connecting any airbag connector, take care not to damage the airbag wire harness.

      3. Check that the waterproof sheet on the top of the center airbag sensor is not folded or deformed.

      4. Check that there is no looseness in the installation parts of the center airbag sensor assembly.

      5. Engage each clamp.

      6. Connect each connector.

      7. Install the 2 bolts.

      8. Install the 2 bolts and connect the 2 earth wires.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
        B001KR1N01
        Text in Illustration
        *1 Center airbag sensor connector *2 Earth wire

    4. for RHD:


      1. Connect the center airbag sensor connectors to the center airbag sensor assembly as shown in the illustration.

        Note

        When connecting any airbag connector, take care not to damage the airbag wire harness.

      2. Check that the waterproof sheet on the top of the center airbag sensor is not folded or deformed.

      3. Check that there is no looseness in the installation parts of the center airbag sensor assembly.

      4. Engage each clamp.

      5. Connect each connector.

      6. Install the 3 bolts.

      7. Install the 2 bolts and connect the 2 earth wires.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
        B001N39N01
        Text in Illustration
        *1 Center airbag sensor connector *2 Earth wire

    5. w/ PTC Heater:


      1. Connect the 2 connectors.

  3. INSTALL ECU INTEGRATION BOX RH (for LHD)

    Click here

  4. INSTALL ECU INTEGRATION BOX RH (for RHD)

    Click here

  5. INSTALL ECU INTEGRATION BOX LH (for RHD)

    Click here

  6. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for LHD)

    Click here

  7. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for RHD)

    Click here

  8. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE


    1. Engage the guide.

    2. Install the center instrument panel to cowl brace with the 2 bolts.

  9. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. Engage the 6 claws.

    2. Install the lower defroster nozzle assembly with the 2 clips.

    3. for RHD:


      1. Engage each clamp.

  10. INSTALL NO. 2 HEATER TO REGISTER DUCT


    1. Install the No. 2 heater to register duct with the 3 clips.

  11. INSTALL REAR NO. 1 AIR DUCT


    1. Engage the 4 claws and install the rear No. 1 air duct.

  12. INSTALL REAR NO. 2 AIR DUCT


    1. Engage the 6 claws and install the rear No. 2 air duct.

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


    1. Install the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.

      Torque:
      Nut
      21.3 N*m  { 217 kgf*cm, 16 ft.*lbf }

    3. Engage each clamp.

    4. Install the bolt and connect the earth wire.

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

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


    1. Install the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

      Torque:
      Nut
      21.3 N*m  { 217 kgf*cm, 16 ft.*lbf }

    3. Engage each clamp.

    4. Install the bolt and connect the earth wire.

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

  15. INSTALL CENTER INSTRUMENT PANEL REINFORCEMENT SUB-ASSEMBLY


    1. Install the center instrument panel reinforcement sub-assembly with the bolt and nut.

  16. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY

    Click here

  17. INSTALL AIR CONDITIONING UNIT ASSEMBLY


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

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

  18. INSTALL STEERING POST ASSEMBLY

    Click here

  19. INSTALL POWER STEERING ECU ASSEMBLY (for LHD)

    Click here

  20. INSTALL POWER STEERING ECU ASSEMBLY (for RHD)

    Click here

  21. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  22. CONNECT OUTLET HEATER WATER HOSE


    1. Using pliers, grip the claws of the clip and slide the clip to connect the outlet heater water hose.

  23. CONNECT INLET HEATER WATER HOSE


    1. Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.

  24. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the pipe.

    2. Apply a sufficient amount of compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring on the air conditioning tube and accessory assembly.

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the air conditioning tube and accessory assembly.

  25. CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the pipe.

    2. Apply a sufficient amount of compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring on the suction pipe sub-assembly.

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the suction pipe sub-assembly.

    5. B001N66

      Move the hook connector in the direction indicated by the arrow in the illustration.

    6. Insert the pipe joint into the fitting hole securely and tighten the bolt.

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

  26. INSTALL RESERVOIR TUBE ASSEMBLY (for RHD)


    1. Install the reservoir tube assembly with the 2 bolts and nut.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  27. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  28. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)

    Click here

  29. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  30. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  31. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for RHD)

    Tech Tips

    Use the same procedure for the RH side and LH side Click here.

  32. ADD COOLANT (for Engine)

    for 2ZR-FXE: Click here

    for 5ZR-FXE: Click here

  33. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))

    Click here

  34. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFO-1234yf(R1234yf))

    Click here

  35. WARM UP COMPRESSOR (for HFC-134a(R134a))

    Click here

  36. WARM UP COMPRESSOR (for HFO-1234yf(R1234yf))

    Click here

  37. INSPECT FOR REFRIGERANT LEAK (for HFC-134a(R134a))

    Click here

  38. INSPECT FOR REFRIGERANT LEAK (for HFO-1234yf(R1234yf))

    Click here

  39. INSPECT FOR COOLANT LEAK (for Engine)

    for 2ZR-FXE: Click here

    for 5ZR-FXE: Click here

  40. INITIALIZE SERVO MOTOR

    Click here