AIR CONDITIONING UNIT(for DENSO Made) INSTALLATION

Info Added 2017-10-06

PROCEDURE


  1. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. A005PGR

      Engage the claws to install the lower defroster nozzle assembly.

  2. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

    Note

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


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

      A005ONQC01
      B00497S Install in this Direction - -
    2. A005OHJ

      Connect the 2 connectors.

    3. Engage the clamps.

    4. Install the 5 bolts.

      A005PEGN01
      Torque:
      Bolt A
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt B
      23.6 N*m  { 241 kgf*cm, 17 ft.*lbf }

    5. Temporarily install the nut.

    6. Install the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  4. CONNECT DRAIN COOLER HOSE


    1. A005P46C03
      *a Cooler Unit Drain Hose Grommet

      Connect the drain cooler hose.

      Note

      If the cooler unit drain hose grommet is disconnected from the vehicle body while connecting the drain cooler hose, make sure to replace it with a new one. Failure to do so may cause water ingress.

  5. INSTALL INSTRUMENT PANEL WIRE


    1. Engage clamps and hook to connect the instrument panel wire.

      A005OM4C02
      *a Clamp *b Hook

    2. Install the instrument panel junction block assembly with main body ECU with the bolt and nut.

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

    3. Install the 2 nuts A.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    4. Install the 4 ground wires with the 4 bolts.

      Torque:
      Bolt B (Part No. 90119-06995)
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }
      Bolt B (Part No. 90119-W0017)
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      Bolt C
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

    5. Install the bolt and screw.

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

    6. Connect each connector.

  6. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. A005OG0

      Install the No. 3 instrument panel to cowl brace sub-assembly with the nut and bolt.

      Torque:
      Bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Engage the clamp and claws.

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


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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. A005OXY

      Engage the clamps to connect the wire harness.

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


    1. A005P9F

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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Temporarily install the screw.

      Tech Tips

      Do not fully tighten the screw.

    3. A005Q45

      Install the ground wire with the bolt.

      Torque:
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

    4. Engage the clamps to connect the wire harness.

    5. Install the relay block assembly with the 2 nuts.

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

  9. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Tighten the 3 bolts, 2 screws and nut in the order shown in the illustration to install the air conditioner unit .

      A005Q4KE01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  10. INSTALL NO. 3 DASH PANEL INSULATOR PAD


    1. A005Q8A

      Engage the clips to install the No. 3 dash panel insulator pad.

    2. A005PZ6C01
      B00497S Install in this Direction

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

    3. Engage the clamps.

    4. Install the clip.

    5. Install the 2 front floor carpet clips.

  11. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)


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

  12. INSTALL ECU INTEGRATION BOX LH

    Click here

  13. INSTALL CLEARANCE WARNING ECU ASSEMBLY (w/ Clearance Sonar System)

    Click here

  14. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY

    Click here

  15. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  16. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  17. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  18. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  19. CONNECT COOLER REFRIGERANT LIQUID PIPE A


    1. Remove the vinyl tape from the cooler refrigerant liquid pipe A.

    2. Apply sufficient compressor oil to a new O-ring and fitting surface of the cooler refrigerant liquid pipe A.

      Compressor Oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the cooler refrigerant liquid pipe A.

      Note

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

    4. Connect the cooler refrigerant liquid pipe A.

  20. CONNECT SUCTION PIPE SUB-ASSEMBLY


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

    2. Apply sufficient compressor oil to a new O-ring and 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 surface free of foreign matter.

    4. Connect the suction pipe sub-assembly.

    5. A005PLB

      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 }

  21. CONNECT INLET HEATER WATER HOSE


    1. A005ON9C01
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (120°)

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

      Note

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

  22. CONNECT OUTLET HEATER WATER HOSE


    1. A005OQSC01
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (120°)

      Connect the outlet heater water hose 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 outlet heater water hose.

  23. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  24. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  25. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  26. INSTALL WATER GUARD PLATE LH

    Click here

  27. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  28. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  29. ADD ENGINE COOLANT

    Click here

  30. INSPECT FOR COOLANT LEAK

    Click here

  31. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  32. WARM UP ENGINE

    Click here

  33. INSPECT FOR REFRIGERANT LEAK

    Click here

  34. INITIALIZATION SERVO MOTOR

    Click here