REAR AIR CONDITIONING UNIT (w/ Heater) INSTALLATION


  1. INSTALL REAR COOLING UNIT ASSEMBLY


    1. Install the rear cooling unit as shown in the illustration.

      A015CYL
    2. A015AMI

      Install the 4 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    3. Connect the 2 connectors.

  2. INSTALL REAR ROOF NO. 1 AIR DUCT

    A0159CK

    1. Install the duct with the clip.

    2. A0155T2

      Attach the 2 claws to install the cooler plate.

  3. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY

    A015D3A

    1. Remove the attached vinyl tape from the pipe.

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

    3. Install 2 O-rings on the air conditioner tube and accessory assembly.

    4. Connect the air conditioner tube and accessory assembly.

    5. Install the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    6. Connect the heater water inlet hose and heater water outlet hose.

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

  4. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH


    1. w/Sliding Roof:

      Click here

    2. w/o Sliding Roof:

      Click here

  5. INSTALL REAR SEAT COVER CAP (w/ Rear No. 2 Seat)


    1. w/Sliding Roof:

      Click here.

    2. w/o Sliding Roof:

      Click here

  6. INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)


    1. Install the tonneau cover assembly.

  7. INSTALL REAR DOOR SCUFF PLATE LH


    1. w/Sliding Roof:

      Click here

    2. w/o Sliding Roof:

      Click here

  8. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE


    1. w/Sliding Roof:

      Click here

    2. w/o Sliding Roof:

      Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  10. ADD ENGINE COOLANT


    1. for 1UR-FE:

      Click here

    2. for 3UR-FE:

      Click here

    3. for 1VD-FTV:

      Click here

  11. 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.

  12. 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.

  13. CHECK FOR ENGINE COOLANT LEAKS


    1. for 1UR-FE:

      Click here

    2. for 3UR-FE:

      Click here

    3. for 1VD-FTV:

      Click here

  14. 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.

  15. CHECK SRS WARNING LIGHT

    Click here

  16. INSTALL UPPER RADIATOR SUPPORT SEAL


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

      A015BVKE02

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


    1. for 1UR-FE:

      Click here

    2. for 3UR-FE:

      Click here

    3. for 1VD-FTV:

      Click here

  18. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. for Standard:

      Click here

    2. w/ Winch:

      Click here

  19. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. for Standard:

      Click here

    2. w/ Winch:

      Click here