FRONT AIR CONDITIONING UNIT (for RHD) INSTALLATION

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 }
INSTALL AIR CONDITIONING HOSE AND ACCESSORY (w/ Cool Box)
1. 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 }
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.
2. Attach the clamps to the wire harness and connect the connectors.
INSTALL HEATER TO REGISTER DUCT ASSEMBLY
1. Attach the 2 claws to install the duct.
2. Install the 3 clips.
INSTALL STEERING COLUMN ASSEMBLY

Click here
INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
1. Attach the 2 claws to install the duct.
2. Install the clip.
INSTALL INSTRUMENT PANEL SUB-ASSEMBLY

Click here
INSTALL FRONT WIPER MOTOR AND BRACKET

Click here
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.
CONNECT AIR CONDITIONING TUBE ASSEMBLY
1. 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:
  
  5.4 N*m { 55 kgf*cm, 47 in.*lbf }
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Click here
ADD ENGINE COOLANT
1. for 1UR-FE:
  
  Click here
2. for 3UR-FE:
  
  Click here

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

CHARGE REFRIGERANT

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

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:
Condenser Core Thickness	Cool Box	Refrigerant Charging Amount
22 mm (0.866 in.)	w/ Cool Box	1010 +/-30 g (35.6 +/-1.1 oz.)
22 mm (0.866 in.)	w/o Cool Box	970 +/-30 g (34.2 +/-1.1 oz.)
16 mm (0.630 in.)	w/ Cool Box	970 +/-30 g (34.2 +/-1.1 oz.)
16 mm (0.630 in.)	w/o Cool Box	920 +/-30 g (32.5 +/-1.1 oz.)

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 100 g (3.53 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.

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 on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
CHECK FOR ENGINE COOLANT LEAK
1. for 1UR-FE:
  
  Click here
2. for 3UR-FE:
  
  Click here
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. 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.
INSTALL UPPER RADIATOR SUPPORT SEAL
1. Install the upper radiator support seal with the 3 clips.
INSTALL ENGINE ROOM SIDE COVER LH
1. Install the engine room side cover LH with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER RH
1. Install the engine room side cover RH with the 7 clips.
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
1. Install the No. 1 engine under cover sub-assembly with the 10 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
1. Push in the clip to install the front fender splash shield sub-assembly LH.
2. Install the 3 bolts and 2 screws.
INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.