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 RHD vehicles.

  • A bolt without a torque specification is shown in the standard bolt chart.

    Click here

PROCEDURE


  1. INSTALL NO. 3 AIR DUCT


    1. B003OK3

      Attach the claw to install the No. 3 air duct.

  2. INSTALL AIR CONDITIONING UNIT ASSEMBLY

    Note


    • Be sure to support the air conditioning unit assembly when installing it because 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. Temporarily install the air conditioning unit assembly and instrument panel reinforcement assembly with the nut.

      B003J3JC01
      *a Standard Position - -

    2. Align the standard position, install the drain cooler hose.

    3. Tighten the nut.

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

  3. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

    B003K3T

    1. Attach the claw to install the lower defroster nozzle assembly.

  4. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

    Note


    • Be sure to support the air conditioning unit assembly when installing it because 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. for Automatic Transmission:

      Install the 11 bolts.

      B003MJYC02
      *A for Manual Transmission - -
      B003R2S Bolt A B003LF2 Bolt B
      B003QHB Bolt C B003PQ8 Bolt D
      Torque:
      Bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. for Manual Transmission:

      Install the 12 bolts.

      Torque:
      Bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    3. B003JOVC02
      *A for Driver Side

      Install 2 new hole plugs.

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


    1. B003LOOC02
      B003R2S Nut
      B003LF2 Bolt
      B003QHB Screw

      Install the No. 1 instrument panel brace sub-assembly with the nut, bolt and 4 screws.

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

    2. Attach the clamp.

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


    1. B003RJLC02
      B003R2S Nut
      B003LF2 Bolt
      B003QHB Screw

      Install the No. 2 instrument panel brace sub-assembly with the nut, bolt and 3 screws.

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

  7. TIGHTEN AIR CONDITIONING UNIT ASSEMBLY


    1. Tighten the 2 screws and 3 bolts in the order shown in the illustration.

      Torque:
      Bolt
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      B003OUBC01
      B003R2S Bolt B003LF2 Screw

  8. CONNECT INSTRUMENT PANEL WIRE


    1. Install each bolt, nut and screw, and then connect the instrument panel wire.

      B003N3JC03
      *A for Manual Air Conditioning System *B for Automatic Air Conditioning System
      *C w/ PTC Heater - -
      *1 Ground Wire - -

    2. Connect each connector and attach each clamp.

    3. Install each bolt and each ground wire.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }
    4. B003KPU

      for Automatic Air Conditioning System:


      1. Attach the clamp.

      2. Connect the connector.

    5. B003NY4

      for Manual Air Conditioning System:


      1. Attach the clamp.

      2. Connect the connector.

  9. INSTALL NO. 1 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003NEK

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

  10. INSTALL NO. 3 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003QA4

      Attach the claw to install the No. 3 rear air duct.

  11. INSTALL NO. 2 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003K6O

      Attach the claw to install the No. 2 rear air duct.

  12. INSTALL NO. 5 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003K6P

      Attach the claw to install the No. 5 rear air duct.

  13. INSTALL NO. 4 REAR AIR DUCT (w/ Rear Foot Duct)


    1. B003JBS

      Attach the claw to install the No. 4 rear air duct.

  14. INSTALL NO. 3 DASH PANEL INSULATOR PAD


    1. B003R2B

      Install the No. 3 dash panel insulator pad.

  15. INSTALL NO. 2 DASH PANEL INSULATOR PAD


    1. B003LO3

      Install the No. 2 dash panel insulator pad.

  16. INSTALL NO. 1 INSTRUMENT PANEL INNER BRACKET COVER LH (for LHD)


    1. B003O9P

      Install the No. 1 instrument panel inner bracket cover LH with the 3 clips.

  17. INSTALL FRONT FLOOR CARPET ASSEMBLY


    1. for RHD:

      Attach the guide to install the front floor carpet assembly to the original position as shown in the illustration.

      B003QBWC01
      B003KT0 Fastener B003OFB Install in this Direction

    2. for LHD:

      Attach the guide to install the front floor carpet assembly to the original position as shown in the illustration.

      B003RUTC02
      B003KT0 Fastener B003OFB Install in this Direction

    3. Attach each fastener.

    4. for RHD:

      Install the 5 clips.

    5. for LHD:

      Install the 6 clips.

  18. INSTALL LOWER CENTER PILLAR GARNISH LH

    Click here

  19. INSTALL LOWER CENTER PILLAR GARNISH RH

    Click here

  20. INSTALL REAR DOOR SCUFF PLATE LH

    Click here

  21. INSTALL REAR DOOR SCUFF PLATE RH

    Click here

  22. INSTALL COWL SIDE TRIM BOARD LH

    Click here

  23. INSTALL FRONT DOOR SCUFF PLATE LH

    Click here

  24. INSTALL COWL SIDE TRIM BOARD RH

    Click here

  25. INSTALL FRONT DOOR SCUFF PLATE RH

    Click here

  26. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  27. INSTALL NO. 2 AIR DUCT


    1. B003L6S

      Attach the claw to install the No. 2 air duct.

      Note

      If the No. 2 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace it with a new one.

    2. Install the bolt.

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

  28. INSTALL NO. 1 AIR DUCT

    B003NDR

    1. Attach the claw to install the No. 1 air duct.

      Note

      If the No. 1 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace it with a new one.

  29. INSTALL TELEMATICS TRANSCEIVER (w/ Telematics Transceiver)

    Click here

  30. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  31. INSTALL FRONT SEAT ASSEMBLY RH


    1. for Manual Seat:

      Click here

    2. for Power Seat:

      Click here

  32. INSTALL FRONT SEAT ASSEMBLY LH

    Tech Tips

    Use the same procedure described for the RH side.

  33. INSTALL HEATER GROMMET

    B003KST

    1. Press the marked parts to attach the claw and install the heater grommet.

      Note


      • Securely install the heater grommet in order to prevent water ingress.

      • Install the heater grommet so that there is no clearance between the grommet and heater pipe.

  34. CONNECT HEATER WATER INLET HOSE


    1. B003Q5CC01
      *a View A
      *b Marking (Yellow)
      *c Clip Installation Angle (40°)
      *d 45°

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

      Note

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

  35. CONNECT HEATER WATER OUTLET HOSE


    1. B003R2XC01
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (40°)

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

      Note

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

  36. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (for 1GD-FTV, 2GD-FTV)


    1. B003KEZ

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

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

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the air conditioner tube and accessory assembly.

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. Connect the air conditioner tube and accessory assembly.

    5. Tighten the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  37. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (except 1GD-FTV, 2GD-FTV)


    1. B003JK1

      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.

      Note

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

    4. Connect the air conditioner tube and accessory assembly.

  38. CONNECT SUCTION PIPE SUB-ASSEMBLY (except 1GD-FTV, 2GD-FTV)


    1. B003LY9

      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.

      Note

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

    4. Connect the suction pipe sub-assembly.

    5. B003MMJC01
      B003OFB Install in this Direction

      Rotate the hook connector as shown in the illustration.

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  39. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY (except 1GD-FTV, 2GD-FTV, w/ Sub-cool Accelerator)


    1. B003PV6

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

    2. Sufficiently apply compressor oil to a new 2 O-rings 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.

      Note

      Keep the O-ring and O-ring fitting surfaces free of foreign matter.

    4. B003Q62C02
      B003OFB Install in this Direction

      Rotate the hook connector as shown in the illustration.

    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  40. INSTALL VACUUM HOSE ASSEMBLY (for GD Series Engine, LHD)


    1. Install the vacuum hose assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Attach the claw.

    3. Connect the vacuum hose with the marking facing left and attach the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the vacuum hose.

      B003NPFC01
      *a View A *b View B
      *c Marking (White) *d Marking (Pink)
      *e Clip Installation Angle (30°) *f Upper
      *g Lower *h Front
      *i Rear j Left
      *k Right - -

  41. INSTALL NO. 2 WIRING HARNESS PROTECTOR (for GD Series Engine, LHD)


    1. B003QA2

      Attach the claw to install the No. 2 wiring harness protector.

    2. Install the 2 nuts.

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

  42. INSTALL VACUUM HOSE ASSEMBLY (for GD Series Engine, RHD)


    1. Install the vacuum hose assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Attach the claw.

    3. Connect the vacuum hose with the marking facing left and attach the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the vacuum hose.

      B003JYPC01
      *a View A *b View B
      *c Marking (White) *d Marking (Pink)
      *e Clip Installation Angle (30°) *f Upper
      *g Lower *h Front
      *i Rear j Left
      *k Right - -

  43. INSTALL NO. 2 WIRING HARNESS PROTECTOR (for GD Series Engine, RHD)


    1. B003JK8

      Attach the claw and guide to install the No. 2 wiring harness protector.

    2. Install the 2 nuts.

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

  44. ADD ENGINE COOLANT


    1. for 1GR-FE:

      Click here

    2. for 1GD-FTV:

      Click here

    3. for 2GD-FTV:

      Click here

    4. for 2TR-FE:

      Click here

    5. for 5L-E:

      Click here

  45. INSPECT FOR COOLANT LEAK


    1. for 1GR-FE:

      Click here

    2. for 1GD-FTV:

      Click here

    3. for 2GD-FTV:

      Click here

    4. for 2TR-FE:

      Click here

    5. for 5L-E:

      Click here

  46. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  47. WARM UP ENGINE

    Click here

  48. INSPECT FOR REFRIGERANT LEAK

    Click here

  49. INITIALIZATION SERVO MOTOR (for Automatic Air Conditioning System)

    Click here