AIR CONDITIONING UNIT(for VALEO Made) INSTALLATION

Info Added 2017-10-06

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles

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

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


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

      A005PKIC01
      B00497S Install in this Direction - -
    2. A005OHJ

      Connect 2 connectors.

    3. Engage the clamps.

    4. Install the 5 bolts.

      Torque:
      Bolt A
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Bolt B
      23.6 N*m  { 241 kgf*cm, 17 ft.*lbf }
      A005PGYN01

    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. A005OBWC01
      *1 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. CONNECT INSTRUMENT PANEL WIRE


    1. for LHD:


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

        A005OGIC03
        *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 4 ground wires with the 4 bolts.

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

      4. Install the bolt and screw.

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

      5. Connect each connector.

    2. for RHD:


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

        A005Q6EC01
        *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. A005OS5

      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. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. for LHD:


      1. A005OFK

        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. 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.

    2. for RHD:


      1. 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.

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


    1. for LHD:


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

        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. A005Q0K

        Engage the clamps to connect the wire harness.

    2. for RHD:


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

        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.

    3. w/ PTC Heater:


      1. Install the bolt to connect the ground wire.

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

    4. 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. for LHD:


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

        A005Q0NN01
        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    2. for RHD:


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

        A005PNGE01
        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  10. INSTALL REAR NO. 1 AIR DUCT (w/ Rear Air Duct)


    1. A005PWUC01
      B00497S Install in this Direction

      Engage the claws to install the rear No. 1 air duct as shown in the illustration.

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


    1. A005OSZC01
      B00497S Install in this Direction

      Engage the claws to install the rear No. 2 air duct as shown in the illustration.

  12. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct)


    1. A005PQ1C01
      B00497S Install in this Direction

      Engage the claws to install the rear No. 3 air duct as shown in the illustration.

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


    1. A005Q6WC01
      B00497S Install in this Direction

      Engage the claws to install the rear No. 4 air duct as shown in the illustration.

    2. A005ORCC01
      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.

  14. INSTALL REAR NO. 5 AIR DUCT (w/ Rear Air Duct)


    1. A005PQSC01
      B00497S Install in this Direction

      Engage the claws to install the rear No. 5 air duct as shown in the illustration.

  15. INSTALL REAR NO. 6 AIR DUCT (w/ Rear Air Duct)


    1. A005P41C01
      B00497S Install in this Direction

      Engage the claws to install the rear No. 6 air duct as shown in the illustration.

  16. INSTALL NO. 3 DASH PANEL INSULATOR PAD


    1. A005Q8A

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

    2. A005PZWC01
      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.

  17. INSTALL COOLER THERMISTOR (ROOM TEMPERATURE SENSOR)


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

  18. INSTALL ECU INTEGRATION BOX RH (for LHD)

    Click here

  19. INSTALL ECU INTEGRATION BOX LH (for RHD)

    Click here

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

    Click here

  21. INSTALL WINDSHIELD WIPER RELAY ASSEMBLY

    Click here

  22. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  23. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  24. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  25. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  26. 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
      VC100YF 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.

  27. CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. Remove the vinyl tape from the suction pipe sub-assembly and cooler refrigerant liquid pipe A.

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

      Compressor Oil
      VC100YF or equivalent

    3. Install the O-ring to the suction pipe sub-assembly and cooler refrigerant liquid pipe A.

      Note

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

    4. Connect the suction pipe sub-assembly and cooler refrigerant liquid pipe A.

    5. Install the bolt.

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

  28. CONNECT INLET HEATER WATER HOSE


    1. A005OQ0C01
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (135°)

      Connect the inlet 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 inlet heater water hose.

  29. CONNECT OUTLET HEATER WATER HOSE


    1. A005OTDC01
      *a View A
      *b Marking (White)
      *c Clip Installation Angle (135°)

      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.

  30. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  31. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  32. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  33. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  34. INSTALL WATER GUARD PLATE LH

    Click here

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

    Click here

  36. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  37. ADD ENGINE COOLANT (for 8NR-FTS)

    Click here

  38. ADD ENGINE COOLANT (for 3ZR-FAE)

    Click here

  39. INSPECT FOR COOLANT LEAK (for 8NR-FTS)

    Click here

  40. INSPECT FOR COOLANT LEAK (for 3ZR-FAE)

    Click here

  41. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))

    Click here

  42. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFO-1234yf(R1234yf))

    Click here

  43. WARM UP ENGINE (for HFC-134a(R134a))

    Click here

  44. WARM UP ENGINE (for HFO-1234yf(R1234yf))

    Click here

  45. INSPECT FOR REFRIGERANT LEAK (for HFC-134a(R134a))

    Click here

  46. INSPECT FOR REFRIGERANT LEAK (for HFO-1234yf(R1234yf))

    Click here

  47. INITIALIZATION SERVO MOTOR

    Click here