FRONT AIR CONDITIONING UNIT (for RHD) INSTALLATION


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Install the air conditioning unit with the 2 nuts.

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

  2. INSTALL AIR CONDITIONING HOSE AND ACCESSORY (w/ Cool Box)


    1. A015D24E02
      Text in Illustration
      *a Correct
      *b Incorrect

      Lubricate 2 new O-rings with compressor oil and install them to the air conditioning hose and accessory.

      Compressor oil
      ND-OIL 8 or equivalent

    2. Install the air conditioning hose and accessory with the piping clamp.

      Note

      After connection, check the claw engagement of the piping clamp.

    3. Install the bolt.

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

  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement.


      1. Install the instrument panel reinforcement with the 7 bolts and screw.

        Torque:
        for bolt
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
        for screw
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. for Passenger Side:

        Using a 12 mm hexagon wrench, install the 2 collars.

        Torque:
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      3. for Passenger Side:

        Using a T40 "TORX" socket, install the 2 "TORX" bolts.

        Torque:
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      4. for Passenger Side:

        Install the 2 caps.

      5. for Driver Side:

        Install the 3 bolts.

        Torque:
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      6. for Driver Side:

        Install the 3 caps.

        A015754

    2. Attach the 17 clamps and 2 claws and install the 9 bolts and 5 nuts.

    3. Connect the connectors to the wire harness.

  4. INSTALL HEATER TO REGISTER DUCT ASSEMBLY


    1. Attach the 2 claws to install the duct.

    2. Install the 3 clips.

  5. INSTALL STEERING COLUMN ASSEMBLY


    1. for Power Tilt and Power Telescopic Steering Column:

      Click here

    2. for Manual Tilt and Manual Telescopic Steering Column:

      Click here

  6. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY


    1. Attach the 2 claws to install the duct.

    2. Install the clip.

  7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  8. INSTALL FRONT WIPER MOTOR AND BRACKET

    Click here

  9. CONNECT HEATER WATER INLET HOSE AND HEATER WATER OUTLET HOSE


    1. Connect the 2 heater water hoses.

    2. Using pliers, grip the claws of the clips and slide the 2 clips.

  10. CONNECT AIR CONDITIONING TUBE ASSEMBLY


    1. A015899E03
      Text in Illustration
      *1 Plate

      Remove the attached vinyl tape from the tubes.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the air conditioning tube assembly.

    4. Connect the air conditioning tube assembly.

    5. Attach the plate as shown in the illustration and install the bolt.

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

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  12. CHECK SRS WARNING LIGHT

    Click here

  13. ADD ENGINE COOLANT


    1. for 1GR-FE:

      Click here

    2. for 1UR-FE:

      Click here

    3. for 3UR-FE:

      Click here

    4. for 1VD-FTV:

      Click here

  14. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard:
      Condenser Core Thickness Air Conditioning Type Cool Box Refrigerant Charging Amount
      22 mm (0.866 in.) w/o Rear Cooler w/ Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/o Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 1010 +/-30 g (35.6 +/-1.1 oz.)
      w/o Cool Box 960 +/-30 g (33.9 +/-1.1 oz.)
      16 mm (0.630 in.) w/o Rear Cooler w/ Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 970 +/-30 g (34.2 +/-1.1 oz.)
      w/o Cool Box 920 +/-30 g (32.5 +/-1.1 oz.)
      A015D7VE19

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  15. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  16. CHECK FOR ENGINE COOLANT LEAK


    1. for 1GR-FE:

      Click here

    2. for 1UR-FE:

      Click here

    3. for 3UR-FE:

      Click here

    4. for 1VD-FTV:

      Click here

  17. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A015C1XE21

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

  18. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the radiator support seal with the 7 clips.

      A015BVKE02

  19. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. for 1GR-FE:

      Click here

    2. for 1UR-FE:

      Click here

    3. for 3UR-FE:

      Click here

    4. for 1VD-FTV:

      Click here

  20. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. for Standard:

      Click here

    2. w/ Winch:

      Click here

  21. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. for Standard:

      Click here

    2. w/ Winch:

      Click here