Click here

AIR CONDITIONING UNIT INSTALLATION

Click here
Click here

PROCEDURE


  1. Click here

    INSTALL DRAIN COOLER HOSE


    1. A0006UWE04

      Align the hose notch and rib as shown in the illustration and install the drain cooler hose.

      Table 1. Text in Illustration
      *a Hose Notch
      *b Rib
  2. Click here

    INSTALL ASPIRATOR PIPE


    1. Engage the 2 claws to install the aspirator pipe.

  3. Click here

    INSTALL COOLER THERMISTOR HOSE


    1. Install the cooler thermistor hose.

    2. Engage the clamp.

  4. Click here

    INSTALL HEATER PACKING


    1. A0005DF

      Install the heater packing as shown in the illustration.

  5. Click here

    INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A0007LZ

      Engage the guide and 2 claws to install the No. 4 air duct sub-assembly as shown in the illustration.

  6. Click here

    INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A0004HE

      Engage the guide and 2 claws to install the No. 1 air duct sub-assembly as shown in the illustration.

  7. Click here

    INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY


    1. A00072Q

      Engage the 2 guides and 2 claws to install the No. 6 heater to register duct assembly as shown in the illustration.

  8. Click here

    INSTALL AIR CONDITIONING HARNESS ASSEMBLY


    1. Engage each clamp to install the air conditioning harness assembly.

    2. Connect each connector.

  9. Click here

    INSTALL BLOWER ASSEMBLY

    for LHD: (Click here)

    for RHD: (Click here)

  10. Click here

    INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. A0005OSE04

      Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

      9.8 N*m 100 kgf*cm 87 in.*lbf
      Note:

      Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.

  11. Click here

    INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT

    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, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. A00077P

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

    2. A0007DVE04

      Install the instrument panel reinforcement assembly with the 3 bolts <A> and 2 new bolts <B> in the order shown in the illustration.

      Table 2. Text in Illustration
      *1 Instrument Panel Reinforcement Assembly - -
      *a Movable Collar *b Body
      *c Step 1 *d Step 2
      *e Step 3 *f Step 4
      20 N*m 204 kgf*cm 15 ft.*lbf
      Note:

      Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

    3. Install the bolt <C>.

      15 N*m 153 kgf*cm 11 ft.*lbf

    4. Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

      9.8 N*m 100 kgf*cm 87 in.*lbf

    5. Pass the drain cooler hose through the vehicle securely.

      Note:

      Connect the cooler drain hose firmly to prevent water leaks.

    6. A0005KBE07

      Install the 2 bolts.

      9.8 N*m 100 kgf*cm 87 in.*lbf
      Note:

      Tighten the bolts in the order shown in the illustration.

    7. Install the 2 hole plugs.

    8. for LHD:


      1. Engage each clamp.

      2. Connect the connector.

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

        8.4 N*m 86 kgf*cm 74 in.*lbf

      4. Connect the protector with the nut.

        8.0 N*m 82 kgf*cm 71 in.*lbf

      5. Connect the connector holder with the 2 nuts.

        8.0 N*m 82 kgf*cm 71 in.*lbf

    9. for RHD:


      1. Engage each clamp.

      2. Connect the connector.

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

        8.4 N*m 86 kgf*cm 74 in.*lbf

      4. Connect the connector holder with the 2 nuts.

        8.0 N*m 82 kgf*cm 71 in.*lbf
    10. A0009KZ

      Engage the claw to connect the airbag connector as shown in the illustration.

    11. A0004EAE09

      Engage the 2 claws to lock the retainer as shown in the illustration.

      Table 3. Text in Illustration
      *a Retainer

    12. Connect the connector.

    13. Install the bolt.

      20 N*m 199 kgf*cm 14 ft.*lbf

    14. for LHD:


      1. Install the shift lever support (Click here).

      2. Install the lower shift lever assembly (Click here).

    15. A0003GHE01

      Engage each clamp.

      Table 4. Text in Illustration
      *1 Airbag Sensor Assembly - -

    16. Connect each connector.

    17. Connect the connector to the airbag sensor assembly as shown in the illustration.

      Note:

      When connecting any airbag connector, take care not to damage the airbag wire harness.

    18. A00080I

      Engage the 3 claws to close the 3 clamps as shown in the illustration.

    19. w/ Telematics Transceiver:


      1. Engage each clamp.

    20. Engage each clamp.

  12. Click here

    INSTALL INSTRUMENT PANEL SAFETY PAD CAP


    1. A0009K6E07

      Install 5 new instrument panel safety pad caps.

      Table 5. Text in Illustration
      *A for LH Side
      *B for RH Side
  13. Click here

    INSTALL NO. 1 HEATER TO REGISTER DUCT


    1. Install the No. 1 heater to register duct with the 3 clips.

    2. Engage the clamp.

  14. Click here

    INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


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

      20 N*m 204 kgf*cm 15 ft.*lbf

    2. Install the screw.

    3. Engage each clamp.

    4. Connect the connector.

    5. Connect the earth wire with the bolt.

      8.4 N*m 86 kgf*cm 74 in.*lbf
  15. Click here

    INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


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

      20 N*m 204 kgf*cm 15 ft.*lbf

    2. Install the screw.

    3. Engage the clamp.

    4. Connect the connector.

  16. Click here

    INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR


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

  17. Click here

    INSTALL NO. 1 CONSOLE BOX DUCT


    1. Install the No. 1 console box duct with the clip.

  18. Click here

    INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET (for LHD)

    Click here

  19. Click here

    INSTALL FLOOR CARPET BRACKET LH


    1. Engage the 2 guides.

    2. Install the floor carpet bracket LH with the 2 clips.

  20. Click here

    INSTALL REAR NO. 2 AIR DUCT


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

  21. Click here

    INSTALL REAR AIR DUCT GUIDE LH


    1. Engage the 4 claws to install the rear air duct guide LH.

    2. A0007DJ

      Engage the guide to install the floor carpet to the original position as shown in the illustration.

  22. Click here

    INSTALL FLOOR CARPET BRACKET RH


    1. Engage the 2 guides.

    2. Install the floor carpet bracket RH with the 2 clips.

  23. Click here

    INSTALL REAR NO. 1 AIR DUCT


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

  24. Click here

    INSTALL REAR AIR DUCT GUIDE RH


    1. Engage the 4 claws to install the rear air duct guide RH.

    2. A0007GI

      Engage the guide to install the floor carpet to the original position as shown in the illustration.

  25. Click here

    INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. A0004K4

      Engage the guide and claw to install the front floor caution plate cover.

  26. Click here

    INSTALL FLOOR CARPET HOOK


    1. Engage the 6 clamps to install the 6 floor carpet hooks.

    2. Engage the 6 guides.

  27. Click here

    INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  28. Click here

    INSTALL ECU INTEGRATION BOX RH

    for LHD: (Click here)

    for RHD: (Click here)

  29. Click here

    INSTALL WIRING HARNESS CLAMP BRACKET (for RHD)


    1. Engage the claw.

    2. Install the wiring harness clamp bracket with the nut.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  30. Click here

    INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    Click here

  31. Click here

    INSTALL HYBRID VEHICLE CONTROL ECU ASSEMBLY

    Click here

  32. Click here

    INSTALL DRIVING SUPPORT ECU ASSEMBLY (w/ Pre-crash Safety System)

    Click here

  33. Click here

    INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

    Click here

  34. Click here

    INSTALL STEERING POST ASSEMBLY

    (Click here)

  35. Click here

    INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    (Click here)

  36. Click here

    INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET

    Click here

  37. Click here

    INSTALL AUDIO AMPLIFIER COVER

    Click here

  38. Click here

    INSTALL FRONT SEAT ASSEMBLY LH

    (Click here)

  39. Click here

    INSTALL TELEMATICS TRANSCEIVER WITH MAYDAY BATTERY (w/ Telematics Transceiver)

    Click here

  40. Click here

    INSTALL AUDIO AMPLIFIER COVER (w/ Telematics Transceiver)

    Click here

  41. Click here

    INSTALL FRONT SEAT ASSEMBLY RH

    Tip:

    Use the same procedure as for the LH side.

  42. Click here

    CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY


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

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

      Compressor oil
      ND-OIL 11 or equivalent

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

    4. Install the air conditioning tube and accessory assembly.

  43. Click here

    CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. 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 11 or equivalent

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

    4. Connect the suction pipe sub-assembly.

    5. A0003JE

      Rotate the hook connector in the direction indicated by the arrow in the illustration.

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

      9.8 N*m 100 kgf*cm 87 in.*lbf
  44. Click here

    CONNECT HEATER INLET WATER HOSE


    1. A0004Z1E03

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

      Table 6. Text in Illustration
      *a View A
      *b Heater Inlet Water Hose Marking (Blue)
      *c Clip installation angle (75 to 105°)
      Note:

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

  45. Click here

    CONNECT HEATER OUTLET WATER HOSE


    1. A0007I8E03

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

      Table 7. Text in Illustration
      *a View A
      *b Heater Outlet Water Hose (Orange)
      *c Clip installation angle (30 to 60°)
      Note:

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

  46. Click here

    CONNECT NO. 1 BRAKE ACTUATOR TUBE


    1. Connect the No. 1 brake actuator tube with the nut.

      5.4 N*m 55 kgf*cm 48 in.*lbf
  47. Click here

    INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: (Click here)

    for RHD: (Click here)

  48. Click here

    INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    (Click here)

  49. Click here

    ADD COOLANT (for Engine)

    Click here

  50. Click here

    INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  51. Click here

    CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  52. Click here

    WARM UP COMPRESSOR

    Click here

  53. Click here

    INSPECT FOR REFRIGERANT LEAK

    Click here

  54. Click here

    INITIALIZE SERVO MOTOR

    (Click here)

  55. Click here

    INSPECT SHIFT LEVER POSITION (for LHD)

    Click here