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


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


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

      A01VAWD

    2. Connect each connector.

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

  2. INSTALL DRAIN COOLER HOSE


    1. A01V9IZC01
      *a Hose Notch
      *b Rib

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

  3. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  4. INSTALL CONSOLE MOUNTING BRACKET RH


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

  5. INSTALL CONSOLE MOUNTING BRACKET LH


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

  6. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. Engage the 2 claws to install the air conditioning duct sub-assembly.

  7. INSTALL BLOWER ASSEMBLY

    Click here

  8. 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 in place.

    2. Connect the drain cooler hose.

  9. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement assembly with the 6 bolts <A>.

      A01V89LN01

    2. Temporarily install the 3 bolts <B>.

  10. 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. Install the front floor carpet assembly to the original position and install the clip.

  11. 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. Install the front floor carpet assembly to the original position and install the clip.

  12. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. Attach each clamp.

      A01V79KC01
      *1 ECU Integration Box RH *2 Instrument Panel Junction Block Assembly

    2. Connect each connector.

    3. Connect the ECU integration box RH with the 2 nuts and bolt.

      Torque:
      for Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      for Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    4. Connect the instrument panel junction block assembly with the 2 bolts.

      Torque:
      3.2 N*m  { 33 kgf*cm, 28 in.*lbf }

    5. Connect the instrument panel wire with the 2 bolts <A>.

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

    6. Connect the ground wire with the 3 bolts.

      Torque:
      for Bolt <B>
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      for Bolt <C>
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    7. w/ PTC Heater:

      Connect the 2 or 3 connectors.

  13. INSTALL INSTRUMENT PANEL WIRE (for RHD)


    1. Attach each clamp.

      A01V7PQC01
      *1 ECU Integration Box RH *2 Instrument Panel Junction Block Assembly
      *3 Engeine Stop and Start ECU - -

    2. Connect each connector.

    3. Connect the ECU integration box RH with the 3 bolts.

      Torque:
      for Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      for Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    4. Connect the instrument panel junction block assembly with the 2 nuts and bolt.

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

    5. Install the engine stop and start ECU with the bolt and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    6. Connect the instrument panel wire with the 3 bolts <A>.

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

    7. Connect the ground wire with the 3 bolts.

      Torque:
      for Bolt <B>
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      for Bolt <C>
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    8. w/ PTC Heater:

      Connect the 2 or 3 connectors.

  14. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. for LHD:

      Tighten the 4 bolts, 2 screws and nut.

      A01V838N01
      Torque:
      for Bolt
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

      Note

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

    2. for RHD:

      Tighten the 4 bolts, 2 screws and nut.

      A01V7V0N01
      Torque:
      for Bolt
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

      Note

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

  15. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. Attach 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.

  16. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. Attach 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.

  17. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. Attach the 3 hooks to install the defroster nozzle assembly.

    2. Connect the automatic light control sensor (solar sensor) connector and attach the 2 harness clamps.

  18. INSTALL AIR DUCT ASSEMBLY


    1. Install the air duct assembly with the 2 nuts.

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

  19. INSTALL REAR NO. 1 AIR DUCT


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

  20. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  21. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  22. CONNECT HEATER WATER HOSE


    1. A01V8COC01
      *a View A
      *b Heater Water Outlet Hose Paint Mark
      *c Heater Water Inlet Hose Paint Mark
      *d Clip installation angle (270°)

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

      Paint Mark Color
      Engine Transmission Hose Color
      2AR All Outlet Purple
      Inlet Purple
      3ZR Manual Transmission Outlet Pink
      Inlet Pink
      CVT Outlet Pink
      Inlet Orange
      1AD, 2AD w/o Fuel Heater Outlet Blue
      Inlet Blue
      w/ Fuel Heater Outlet Grean
      Inlet Grean

      Note

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

  23. CONNECT AIR CONDITIONING TUBE


    1. A01V9H4

      Remove the vinyl tape from the suction tube sub-assembly and liquid tube sub-assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the suction tube sub-assembly and liquid tube sub-assembly.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the suction tube sub-assembly liquid tube sub-assembly.

    4. Connect the liquid tube sub-assembly and suction tube sub-assembly.

    5. Rotate 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 }

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  25. ADD ENGINE COOLANT

    for 1AD-FTV: Click here

    for 2AD-FHV: Click here

    for 2AD-FTV: Click here

    for 2AR-FE: Click here

    for 3ZR-FAE: Click here

    for 3ZR-FE: Click here

  26. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  27. WARM UP ENGINE

    Click here

  28. INSPECT FOR COOLANT LEAK

    for 1AD-FTV: Click here

    for 2AD-FHV: Click here

    for 2AD-FTV: Click here

    for 2AR-FE: Click here

    for 3ZR-FAE: Click here

    for 3ZR-FE: Click here

  29. INSPECT FOR REFRIGERANT LEAK

    Click here

  30. INITIALIZATION SERVO MOTOR

    for Automatic Air Conditioning system: Click here