FRONT AIR CONDITIONING UNIT INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE

INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
1. Attach the 2 claws to install the instrument panel reinforcement assembly.
2. Install the 5 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY
1. Install the instrument panel reinforcement assembly with air conditioning unit assembly.
  1. Install the bolts and nuts and instrument panel reinforcement assembly with air conditioning unit assembly.
  2. Using a 8 mm hexagon wrench, tighten the 2 collars.
    
    Torque:
    
    27 N*m { 275 kgf*cm, 20 ft.*lbf }
  3. Using a T40 "TORX" socket, install the 5 "TORX" bolts.
    
    Torque:
    
    27 N*m { 275 kgf*cm, 20 ft.*lbf }
  4. Install the 5 caps.
  5. Attach the clamps and connectors to the wire harness.
  6. Install the bolts and nuts.
INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY
1. Attach the 3 claws to install the No. 1 air duct sub-assembly.
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.
INSTALL NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET LH
1. Install the No. 1 instrument panel brace mounting bracket LH with the 2 nuts and bolt.
INSTALL NO. 1 INSTRUMENT PANEL BRACE MOUNTING BRACKET RH
1. Install the No. 1 instrument panel brace mounting bracket RH with the 2 nuts and bolt.
INSTALL NO. 1 CONSOLE BOX DUCT
1. Install the No. 1 console box duct with the clip.
INSTALL REAR NO. 3 AIR DUCT
1. Attach the 6 claws and 3 clamps to install the rear No. 3 air duct.
INSTALL REAR NO. 1 AIR DUCT
1. Attach the 6 claws and 3 clamps to install the rear No. 1 air duct.
INSTALL FRONT CARPET ASSEMBLY
1. Install the front floor carpet assembly.
INSTALL FRONT SEAT ASSEMBLY LH
1. for Manual Seat:
  
  Install the front seat assembly LH Click here.
2. for Power Seat:
  
  Install the front seat assembly LH Click here.
3. for Walk in Seat Type:
  
  Install the front seat assembly LH Click here.
4. for Bench Seat Type:
  
  Install the front seat assembly LH Click here.
INSTALL FRONT SEAT ASSEMBLY RH
1. for Manual Seat:
  
  Install the front seat assembly RH Click here.
2. for Power Seat:
  
  Install the front seat assembly RH Click here.
3. for Walk in Seat Type:
  
  Install the front seat assembly RH Click here.
4. for Bench Seat Type:
  
  Install the front seat assembly RH Click here.
INSTALL STEERING COLUMN ASSEMBLY
1. for Manual Tilt and Manual Telescopic Steering Column:
  
  Install the steering column assembly Click here.
2. for Power Tilt and Power Telescopic Steering Column:
  
  Install the steering column assembly Click here.
INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
1. Install the instrument panel sub-assembly Click here.
INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
1. Install the windshield wiper motor assembly Click here.

CONNECT HEATER WATER INLET HOSE AND OUTLET HOSE

Connect the 2 heater water hose.

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

Text in Illustration
*A	for 1GR-FE, for Single Air Conditioning System	*B	for 1KD-FTV, for Single Air Conditioning System
*C	for 5L-E, for Single Air Conditioning System	*D	for 2TR-FE, for Single Air Conditioning System
*E	for 1GR-FE, for Dual Air Conditioning System	*F	for 1KD-FTV, Dual Air Conditioning System
*G	for 5L-E, Dual Air Conditioning System	*H	for 2TR-FE, Dual Air Conditioning System
*I	for Dual Air Conditioning System, for LHD	*J	for Dual Air Conditioning System, for RHD
*K	for 1GD-FTV, for Single Air Conditioning System	*L	for 1GD-FTV, for Dual Air Conditioning System
*M	for 1GD-FTV, for Single Air Conditioning System w/ Combustion Type Power Heater	*N	for 1GD-FTV, for Dual Air Conditioning System w/ Combustion Type Power Heater
*a	Green Marking	*b	Blue Marking
*c	Orange Marking	*d	Yellow Marking
*e	White Marking	*f	Pink Marking
*g	Red Marking	*h	Purple Marking

CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for Bolt Joint Type)
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube and accessory assembly.
  
  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 assembly.
4. Install the 2 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for Quick Joint Type)
1. Install the grommet.
2. Install the 2 O-rings to the air conditioning tube and accessory assembly.
3. Text in Illustration
  
  *a CORRECT
  
  *b INCORRECT
  
  Connect the air conditioning tube and accessory assembly with the piping clamp.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
  
  Note
  
  After the connection, check that the claw of the piping clamp is attached.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Click here
ADD ENGINE COOLANT
1. for 1GR-FE:
  
  Add engine coolant Click here.
2. for 2TR-FE:
  
  Add engine coolant Click here.
3. for 1KD-FTV:
  
  Add engine coolant Click here.
4. for 5L-E:
  
  Add engine coolant Click here.
5. for 1GD-FTV:
  
  Add engine coolant Click here.
WARM UP ENGINE

Click here
INSPECT FOR COOLANT LEAK
1. for 1GR-FE:
  
  Inspect for coolant leak Click here.
2. for 2TR-FE:
  
  Inspect for coolant leak Click here.
3. for 1KD-FTV:
  
  Inspect for coolant leak Click here.
4. for 5L-E:
  
  Inspect for coolant leak Click here.
5. for 1GD-FTV:
  
  Inspect for coolant leak Click here.
CHECK FOR REFRIGERANT GAS LEAK

Click here
INSTALL UPPER RADIATOR SUPPORT SEAL

Click here
CHECK SRS WARNING LIGHT
1. Check the SRS warning light Click here.

Text in Illustration
*a	CORRECT
*b	INCORRECT