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 LHD vehicles.

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

    Click here

PROCEDURE


  1. INSTALL NO. 3 AIR DUCT


    1. B0027NY

      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.

      B00278WC02
      *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 DEFROSTER NOZZLE ASSEMBLY

    B00279A

    1. Attach the claw to install the 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.

      B002912C04
      *A for Manual Transmission - -
      B0068HS Bolt A B006964 Bolt B
      B0069AV Bolt C B0068S6 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. B002851C03
      *A for Driver Side

      Install 2 new hole plugs.

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


    1. B00260ZC02
      B0068HS Nut
      B006964 Bolt
      B0069AV 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. B0028P4C02
      B0068HS Nut
      B006964 Bolt
      B0069AV 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 }
      B00253OC01
      B0068HS Bolt B006964 Screw

  8. CONNECT INSTRUMENT PANEL WIRE


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

      B0026SJC03
      *A for Automatic Air Conditioning System *B for Manual Air Conditioning System, Manual Cooler System
      *C w/ PTC Heater *D w/ Stop and Start System
      *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. B002756

      for Automatic Air Conditioning System:


      1. Attach the clamp.

      2. Connect the connector.

    5. B0026K0

      for Manual Air Conditioning System, Manual Cooler System:


      1. Attach the clamp.

      2. Connect the connector.

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


    1. B0028EQ

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

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


    1. B00280G

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

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


    1. B0028GM

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

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


    1. B0024VN

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

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


    1. B0026W1

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

  14. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Resistor Duct)


    1. B00283J

      for Automatic Transmission:


      1. Install the No. 1 console box duct with the 2 clips.

      2. B0025UZC03
        *A w/ Entry and Start System

        w/ Entry and Start System:

        Attach the clamp to install the No. 2 console box mounting bracket.

      3. Install the 2 bolts.

    2. B0028WB

      for Manual Transmission:


      1. Install the No. 1 console box duct with the 3 clips.

      2. B0028XPC02
        *A w/ Entry and Start System

        w/ Entry and Start System:

        Attach the clamp to install the No. 2 console box mounting bracket.

      3. Install the 2 bolts.

  15. INSTALL NO. 3 DASH PANEL INSULATOR PAD


    1. B00289I

      Install the No. 3 dash panel insulator pad.

  16. INSTALL NO. 2 DASH PANEL INSULATOR PAD


    1. B0027XO

      Install the No. 2 dash panel insulator pad.

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


    1. B00270E

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

  18. INSTALL FRONT FLOOR CARPET ASSEMBLY


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

      B0026BXC04
      *A for LHD - -
      B00692L Fastener B0069FO Install in this Direction

    2. Attach each fastener.

    3. for LHD:

      Install the 5 clips.

    4. for RHD:

      Install the 4 clips.

  19. INSTALL LOWER CENTER PILLAR GARNISH LH (for Double Cab)

    Click here

  20. INSTALL LOWER CENTER PILLAR GARNISH RH (for Double Cab)

    Click here

  21. INSTALL REAR DOOR SCUFF PLATE LH (for Double Cab)

    Click here

  22. INSTALL REAR DOOR SCUFF PLATE RH (for Double Cab)

    Click here

  23. INSTALL COWL SIDE TRIM BOARD LH

    Click here

  24. INSTALL FRONT DOOR SCUFF PLATE LH


    1. for Double Cab:

      Click here

    2. for Single Cab:

      Click here

    3. for Smart Cab:

      Click here

  25. INSTALL COWL SIDE TRIM BOARD RH

    Click here

  26. INSTALL FRONT DOOR SCUFF PLATE RH


    1. for Double Cab:

      Click here

    2. for Single Cab:

      Click here

    3. for Smart Cab:

      Click here

  27. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  28. INSTALL NO. 1 AIR DUCT


    1. B0026JT

      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.

    2. Install the bolt.

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

  29. INSTALL NO. 2 AIR DUCT

    B0027KE

    1. 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.

  30. INSTALL TELEPHONE TRANSCEIVER ASSEMBLY (w/ Telematics Transceiver)

    Click here

  31. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  32. INSTALL CONSOLE BOX ASSEMBLY (w/ Console Box Lid)

    Click here

  33. INSTALL FRONT CONSOLE BOX (w/o Console Box Lid)

    Click here

  34. INSTALL FRONT SEAT ASSEMBLY LH


    1. for Manual Seat:

      Click here

    2. for Power Seat:

      Click here

    3. for Bench Seat Type:

      Click here

  35. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  36. INSTALL HEATER GROMMET (w/ Heater)

    B00261L

    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.

  37. CONNECT HEATER WATER INLET HOSE (w/ Heater)


    1. B00261SC02
      *a View A
      *b

      for 1GR-FE: Marking (Yellow)

      for 1GD-FTV, 2GD-FTV: Marking (Yellow)

      for 2KD-FTV: Marking (Yellow)

      for 1TR-FE, 2TR-FE: Marking (Yellow)

      for 5L-E: Marking (Yellow)
      *c Clip Installation Angle (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.

  38. CONNECT HEATER WATER OUTLET HOSE (w/ Heater)


    1. B0025QCC01
      *a View A
      *b

      for 1GR-FE: Marking (White)

      for 1GD-FTV, 2GD-FTV: Marking (White)

      for 2KD-FTV: Marking (White)

      for 1TR-FE, 2TR-FE: Marking (White)

      for 5L-E: 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.

  39. INSTALL INTAKE AIR SURGE TANK (for 1GR-FE)

    Click here

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


    1. B0025XS

      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.

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


    1. B00262B

      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. B0028JGC01
      B0069FO 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 }

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


    1. B0026BI

      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 }

  43. 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.

      B0025B3C01
      *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 - -

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


    1. B0028H2

      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 }

  45. 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.

      B0026X6C01
      *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 - -

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


    1. B0026M1

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

    2. Install the nut.

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

  47. ADD ENGINE COOLANT (w/ Heater)


    1. for 1GR-FE:

      Click here

    2. for 1GD-FTV:

      Click here

    3. for 2GD-FTV:

      Click here

    4. for 2KD-FTV:

      Click here

    5. for 1TR-FE:

      Click here

    6. for 2TR-FE:

      Click here

    7. for 5L-E:

      Click here

  48. INSPECT FOR COOLANT LEAK (w/ Heater)


    1. for 1GR-FE:

      Click here

    2. for 1GD-FTV:

      Click here

    3. for 2GD-FTV:

      Click here

    4. for 2KD-FTV:

      Click here

    5. for 1TR-FE:

      Click here

    6. for 2TR-FE:

      Click here

    7. for 5L-E:

      Click here

  49. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  50. WARM UP ENGINE

    Click here

  51. INSPECT FOR REFRIGERANT LEAK

    Click here

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

    Click here