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.

PROCEDURE


  1. INSTALL BLOWER ASSEMBLY

    Click here

  2. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. A002PUX

      Attach the 2 claws to install the No. 3 air duct sub-assembly.

  3. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. A002OXP

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

  4. TEMPORARILY INSTALL AIR CONDITIONING UNIT


    1. A002MYP

      Temporarily install the air conditioning unit with the bolt and nut.

      Note


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

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

  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement assembly with the 8 bolts.

      A002OFW

    2. Connect each connector.

    3. Attach each clamp.

    4. Connect the wire harness and junction block and install each bolt.

      Torque:
      for bolt A
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      A002N22E02
      Text in Illustration
      *A except Manual Transaxle *B w/ PTC Heater
      *1 Specified Torque Bolt A - -

    5. Attach each clamp and connect the wire harness.

    6. Install the ground wire with the 2 bolts.

      A002N6V

  6. INSTALL AIR CONDITIONING UNIT

    A002Q87

    1. Tighten the bolt of the air conditioning unit.

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

    2. Tighten the nut of the air conditioning unit.

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

    3. Connect the drain cooler hose.

  7. INSTALL REAR NO. 2 AIR DUCT


    1. A002PBR

      Attach the 4 claws to install the rear No. 2 air duct.

  8. INSTALL INSTRUMENT PANEL BRACE ASSEMBLY

    A002LJDE02
    Text in Illustration
    *A except Manual Transaxle
    *1 Screw

    1. Install the instrument panel brace assembly with the 3 bolts, 2 screws and 2 nuts.

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

    2. Attach each clamp.

    3. Connect the connector.

  9. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE


    1. A002M1Y

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

  10. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A002MZE

      Attach the 6 claws to install the lower defroster nozzle assembly.

  11. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A002NR2

      Install the No. 1 air duct sub-assembly with the 2 nuts.

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

  12. INSTALL REAR NO. 1 AIR DUCT


    1. A002P1M

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

    2. A002P0U

      Install the floor carpet with the clip.

  13. INSTALL REAR NO. 3 AIR DUCT


    1. A002OJG

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

    2. A002OTJ

      Install the floor carpet with the clip.

  14. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  15. INSTALL COWL SIDE TRIM BOARD LH

    Click here

  16. INSTALL FRONT DOOR SCUFF PLATE LH

    Click here

  17. INSTALL COWL SIDE TRIM BOARD RH

    Click here

  18. INSTALL FRONT DOOR SCUFF PLATE RH

    Click here

  19. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  20. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  21. CONNECT HEATER OUTLET WATER HOSE AND HEATER INLET WATER HOSE


    1. A002MQFE01
      Text in Illustration
      *1 Paint Mark (Width: 5 mm)
      *2 Paint Mark (Width: 2 mm)

      Connect the heater outlet water hose and heater inlet water hose with the paint mark facing up and attach the clip shown in the illustration.

  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. A002MML

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


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

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

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Connect the air conditioner tube and accessory assembly.

  24. CONNECT SUCTION PIPE SUB-ASSEMBLY (for HFC-134a(R134a))


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

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. A002PN6

      Securely connect the suction pipe 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 }

  25. INSTALL OUTER COWL TOP PANEL

    Click here

  26. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)

    Click here

  27. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  28. INSTALL COWL TOP VENTILATOR LOUVER LH

    Click here

  29. INSTALL COWL TOP VENTILATOR LOUVER RH

    Click here

  30. INSTALL HOOD TO COWL TOP SEAL

    Click here

  31. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

    Click here

  32. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

    Click here

  33. INSTALL FRONT WIPER ARM HEAD CAP

    Click here

  34. INSTALL NO. 2 CYLINDER HEAD COVER (for ZR Series Engine)

    Click here

  35. INSTALL NO. 1 ENGINE COVER (for 1WW)

    Click here

  36. CHARGE REFRIGERANT


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  37. ADD ENGINE COOLANT (for 1ZR-FAE)

    Click here

  38. ADD ENGINE COOLANT (for 2ZR-FAE)

    Click here

  39. ADD ENGINE COOLANT (for 1WW)

    Click here

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    CAUTION:

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

  41. INSPECT FOR COOLANT LEAK (for 1ZR-FAE)

    Click here

  42. INSPECT FOR COOLANT LEAK (for 2ZR-FAE)

    Click here

  43. INSPECT FOR COOLANT LEAK (for 1WW)

    Click here

  44. CHECK SRS WARNING LIGHT

    Click here

  45. WARM UP ENGINE


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  46. CHECK FOR REFRIGERANT GAS LEAK


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here