AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)


    1. Route the air conditioning harness assembly as shown in the illustration.

      A01LXO9C01
      *A for Dual Type - -

    2. Connect each connector.

    3. Engage each clamp to install the air conditioning harness assembly.

  2. INSTALL DRAIN COOLER HOSE


    1. A01LXQIC01
      *a Hose Notch
      *b Rib

      Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.

  3. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (for Manual Air Conditioning System)


    1. Temporarily install the air conditioning amplifier assembly as shown in the illustration.

      A01M2IV

    2. Install the air conditioning amplifier assembly with the screw.

  4. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (for Automatic Air Conditioning System)


    1. Temporarily install the air conditioning amplifier assembly as shown in the illustration.

      A01LWJG

    2. Install the air conditioning amplifier assembly with the screw.

    3. Connect the connector.

  5. INSTALL CONSOLE MOUNTING BRACKET RH


    1. Engage the 2 claws to install the console mounting bracket RH.

  6. INSTALL CONSOLE MOUNTING BRACKET LH


    1. Install the console mounting bracket LH with the screw.

  7. INSTALL ASPIRATOR PIPE (w/o Cooler System)


    1. Engage the 2 claws to install the aspirator pipe.

  8. INSTALL ASPIRATOR (for Automatic Air Conditioning System)


    1. for LHD:


      1. Engage the 2 claws to install the aspirator.

    2. for RHD:


      1. Engage the 2 claws to install the aspirator.

      2. Engage the clamp.

  9. INSTALL HEATER COVER (except Cold Area)


    1. Engage the 4 claws to install the heater cover.

  10. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY


    1. Install the air conditioning radiator assembly with the 3 screws.

    2. for Automatic Air Conditioning System:


      1. Connect the connector.

    3. for Cold Area:


      1. Engage each clamp.

      2. Connect the wire harness with the screw.

  11. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


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

      Note

      If any of the claws of the No. 3 air duct sub-assembly are cracked or deformed, make sure to replace the air duct with a new one. Failure to do so may cause the No. 3 air duct sub-assembly to fall off or noise to occur.

  12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


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

      Note

      If any of the claws of the No. 2 air duct sub-assembly are cracked or deformed, make sure to replace the air duct with a new one. Failure to do so may cause the No. 2 air duct sub-assembly to fall off or noise to occur.

  13. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Temporarily install the air conditioner unit assembly with the bolt and nut.

      Note

      To prevent damage to the installation bracket for the air conditioner unit assembly, be sure to support the air conditioner unit assembly.

    2. Connect the drain cooler hose.

  14. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


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

      A01M21FC01
      A01M03W Bolt <A> A01LZQW Bolt <B>

    2. Temporarily install the 3 bolts <B>.

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


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

      Tech Tips

      Do not fully tighten the screw.

    2. A01M1M1

      Install the front floor carpet assembly to the original position as shown in the illustration.

    3. Install the clip.

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


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

      Tech Tips

      Do not fully tighten the screw.

    2. A01M11K

      Install the front floor carpet assembly to the original position as shown in the illustration.

    3. Install the clip.

  17. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. Engage each clamp.

      A01LW2CC01
      *A w/ ECU Integration Box RH *B w/o Radio Receiver
      *C for Automatic Air Conditioning System *D for Manual Air Conditioning System
      *a Ground Portion of the Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01M03W Bolt <A> A01LZQW Bolt <B>
      A01LWTP Bolt <C> A01M0E2 Connector

    2. Connect each connector.

    3. w/ ECU Integration Box RH:


      1. Engage the guide to connect the ECU integration box RH.

      2. Install the 3 bolts <C>.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    4. Connect the instrument panel wire with the 5 bolts <B>.

    5. Connect the ground portion of the wiring harness protector cover and earth wire with the 2 bolts <A>.

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

    6. for Cold Area:


      1. Connect the 2 connectors.

  18. INSTALL INSTRUMENT PANEL WIRE (for RHD)


    1. Engage each clamp.

      A01LXRTC01
      *A w/ ECU Integration Box RH *B w/o Radio Receiver
      *C for Manual Air Conditioning System *D for Automatic Air Conditioning System
      *a Ground Portion of the Wiring Harness Protector Cover *b Earth Wire
      *c Guide *d Clamp
      A01M03W Bolt <A> A01LZQW Bolt <B>
      A01LWTP Bolt <C> A01M0E2 Connector

    2. Connect each connector.

    3. w/ ECU Integration Box RH:


      1. Engage the guide to connect the ECU integration box RH.

      2. Install the 3 bolts <C>.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    4. Connect the instrument panel wire with the 4 bolts <B>.

    5. Connect the ground portion of the wiring harness protector cover and earth wire with the 2 bolts <A>.

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

    6. for Cold Area:


      1. Connect the 2 connectors.

  19. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY (for LHD)


    1. Tighten the 4 bolts, 2 screws and nut.

      A01M14FC03
      A01M03W Bolt A01LZQW Screw
      A01LWTP Nut - -
      Torque:
      Bolt, Nut
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Screw
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      Note

      Tighten the bolts, screws and nut in the order shown in the illustration to install the air conditioner unit assembly.

  20. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY (for RHD)


    1. Tighten the 4 bolts, 2 screws and nut.

      A01LZZ0C03
      A01M03W Bolt A01LZQW Screw
      A01LWTP Nut - -
      Torque:
      Bolt, Nut
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Screw
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      Note

      Tighten the bolts, screws and nut in the order shown in the illustration to install the air conditioner unit assembly.

  21. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE


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

  22. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. Engage the 6 claws to install the defroster nozzle assembly.

  23. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)


    1. Connect the connector and aspirator to install the cooler (room temp. sensor) thermistor.

  24. INSTALL REAR NO. 1 AIR DUCT (for Cold Area)


    1. Engage the 8 claws to install the rear No. 1 air duct.

  25. INSTALL DRIVING SUPPORT ECU ASSEMBLY (for 1ND-TV)

    w/ Cruise Control System:

    Click here

  26. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for LHD)

    Click here

  27. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for RHD)

    Click here

  28. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  29. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  30. CONNECT HEATER WATER INLET HOSE A


    1. A01LZSKC01
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (270°)

      Connect the heater water inlet hose A with the marking (white) facing up and engage the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the heater water inlet hose A.

  31. CONNECT HEATER WATER OUTLET HOSE A


    1. A01LVSIC01
      *a View A
      *b Marking (white)
      *c Clip Installation Angle (270°)

      Connect the heater water outlet hose A with the marking (white) facing up and engage the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the heater water outlet hose A.

  32. INSTALL COOLER CAP (w/o Cooler System)


    1. Sufficiently apply compressor oil to the 2 O-rings.

      Compressor Oil
      ND-OIL 8 or equivalent

    2. Install the cooler cap with the bolt.

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

  33. CONNECT AIR CONDITIONER TUBE ASSEMBLY (w/ Cooler System)


    1. Remove the vinyl tape from the air conditioner tube assembly.

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

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioner tube assembly.

    4. Install the air conditioner tube assembly.

  34. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Cooler System)


    1. Remove the vinyl tape from the suction pipe sub-assembly.

    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. Connect the suction pipe sub-assembly.

    5. A01LXOI

      Rotate the hook connector as shown in the illustration.

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

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

  35. INSTALL OUTER COWL TOP PANEL (for 1AD-FTV, 1ND-TV)

    for LHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

    for RHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  36. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for 1AD-FTV, 1ND-TV)

    for LHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

    for RHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  37. INSTALL WATER GUARD PLATE LH (for 1AD-FTV, 1ND-TV)

    for LHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

    for RHD:

    for Sedan: Click here

    for Hatchback, Wagon: Click here

  38. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for 1AD-FTV)

    Click here

  39. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 1AD-FTV, 1ND-TV)

    Click here

  40. INSPECT FOR COOLANT LEAK (for 1AD-FTV)

    Click here

  41. INSPECT FOR COOLANT LEAK (for 1ND-TV)

    Click here

  42. INSPECT FOR COOLANT LEAK (for 1NR-FE)

    Click here

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

    Click here

  44. INSPECT FOR COOLANT LEAK (for 1ZR-FE)

    Click here

  45. INSPECT FOR COOLANT LEAK (for 2ZR-FE)

    Click here

  46. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1AD-FTV)

    Click here

  47. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1ND-TV)

    Click here

  48. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1NR-FE)

    Click here

  49. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1ZR-FAE)

    Click here

  50. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1ZR-FE)

    Click here

  51. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 2ZR-FE)

    Click here

  52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Cooler System)

    Click here

  53. WARM UP ENGINE (w/ Cooler System)

    Click here

  54. INSPECT FOR REFRIGERANT LEAK (w/ Cooler System)

    Click here

  55. INITIALIZE SERVO MOTOR (for Automatic Air Conditioning System)

    Click here