FRONT AIR CONDITIONING UNIT INSTALLATION

PROCEDURE


  1. TEMPORARILY INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Engage the 2 claws.

    2. Temporarily install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    Note


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

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


    1. Engage the 3 guides to temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.

      B00400B

    2. Install the 6 bolts as shown in the illustration.

      B003Z5BC01
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Vehicle Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
      B003ZIE Bolt B003Z8F Nut
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Temporarily install the nut.

    4. Connect the drain cooler hose.

    5. Install the 2 hole plugs.

    6. Engage the claw to connect the drain cooler hose to the piping clamp.

    7. Install the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    8. Install the 2 hole plugs.

    9. Engage each clamp.

    10. Connect each connector.

    11. for LHD:


      1. Connect the 4 earth wires with the 4 bolts.

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

    12. for RHD:


      1. Connect the 3 earth wires with the 3 bolts.

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

  3. INSTALL INSTRUMENT PANEL SAFETY PAD CAP


    1. B003Z2CC01
      *A for LH Side
      *B for RH Side

      Install 4 new instrument panel safety pad caps.

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


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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Do not fully tighten the screw.

    2. Engage each clamp.

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


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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Do not fully tighten the screw.

    2. Connect the earth wire with the bolt.

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

    3. Engage each clamp.

  6. FULLY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY


    1. for LHD:


      1. Tighten the 3 bolts, 2 screws and nut.

        B003ZTBC01
        B003ZIE Bolt B003Z8F Screw
        B003ZMU Nut - -
        Torque:
        Bolt
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
        Nut
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

        Note

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

    2. for RHD:


      1. Tighten the 3 bolts, 2 screws and nut.

        B003Z2EC01
        B003ZIE Bolt B003Z8F Screw
        B003ZMU Nut - -
        Torque:
        Bolt
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
        Nut
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

        Note

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

  7. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

    Click here

  8. INSTALL SHIFT LEVER SUPPORT


    1. B003ZBUC02
      B003ZIE Nut
      B003Z8F Bolt

      Install the 2 nuts.

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

      Note

      Tighten the nuts in the order shown in the illustration.

    2. Install the shift lever support with the 4 bolts.

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

    3. Engage each clamp.

    4. Connect each connector.

  9. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

    for U660E Automatic Transmission / Transaxle:

    Click here

    for U660F Automatic Transmission / Transaxle:

    Click here

    for U760E Automatic Transmission / Transaxle:

    Click here

  10. INSTALL REAR NO. 3 AIR DUCT


    1. Engage the 2 claws to install the rear No. 3 air duct.

  11. INSTALL REAR NO. 4 AIR DUCT


    1. Install the rear No. 4 air duct with the clip.

    2. B004089C01
      B004057 Fastener

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

    3. Engage the fastener and 4 guides.

  12. INSTALL REAR NO. 1 AIR DUCT


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

    2. Engage the clamp to connect the wire harness.

  13. INSTALL REAR NO. 2 AIR DUCT


    1. Install the rear No. 2 air duct with the clip.

    2. B00407CC01
      B004057 Fastener

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

    3. Engage the 2 fasteners and 4 guides.

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


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

  15. INSTALL WIRE HARNESS CLAMP BRACKET (for LHD)


    1. Install the wire harness clamp bracket with the nut.

    2. Engage the 3 clamps.

  16. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    for LHD:

    Click here

    for RHD:

    Click here

  17. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  18. INSTALL ECU INTEGRATION BOX RH (for LHD)

    w/ ECU Integration Box:

    Click here

  19. INSTALL ECU INTEGRATION BOX LH (for RHD)

    w/ ECU Integration Box:

    Click here

  20. INSTALL STEERING POST ASSEMBLY

    Click here

  21. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  22. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)

    Click here

  23. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)

    Click here

  24. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)

    Tech Tips

    Use the same procedure as for the LH side.

  25. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)

    Tech Tips

    Use the same procedure as for the LH side.

  26. CONNECT INLET HEATER WATER HOSE


    1. B003ZH2C01
      *a View A
      *b

      for 2GR-FE:

      Marking (Blue)

      for 1AR-FE:

      Marking (Orange)
      *c Clip Installation Angle (60 to 120°)

      Connect the inlet heater water hose with the marking facing left and engage the clip within the area shown in the illustration.

      Note

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

  27. CONNECT OUTLET HEATER WATER HOSE


    1. B003ZY1C01
      *a View A
      *b

      for 2GR-FE:

      Marking (Blue)

      for 1AR-FE:

      Marking (Orange)
      *c Clip Installation Angle (15 to 75°)

      Connect the outlet heater water hose with the marking facing left and engage the clip within the area shown in the illustration.

      Note

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

  28. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


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

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

      Compressor Oil
      ND-OIL 8 or equivalent

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

    4. Connect the air conditioner tube and accessory assembly.

  29. CONNECT SUCTION HOSE SUB-ASSEMBLY


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

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

      Compressor Oil
      ND-OIL 8 or equivalent

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

    4. Connect the suction hose sub-assembly.

    5. B00403S

      Rotate the hook connector as shown in the illustration.

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

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

  30. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for 2GR-FE)

    for LHD:

    Click here

    for RHD:

    Click here

  31. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 2GR-FE)

    Click here

  32. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  33. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

    Click here

  34. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

    Click here

  35. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

    Click here

  36. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

    Click here

  37. INSTALL FRONT WIPER ARM HEAD CAP

    Click here

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  39. ADD ENGINE COOLANT (for 1AR-FE)

    Click here

  40. ADD ENGINE COOLANT (for 2GR-FE)

    Click here

  41. INSPECT FOR COOLANT LEAK (for 1AR-FE)

    Click here

  42. INSPECT FOR COOLANT LEAK (for 2GR-FE)

    Click here

  43. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  44. WARM UP ENGINE

    Click here

  45. INSPECT FOR REFRIGERANT LEAK

    Click here

  46. INITIALIZE SERVO MOTOR (for Manual Air Conditioning System)

    Click here

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

    Click here