REAR AIR CONDITIONING UNIT INSTALLATION

INSTALL REAR COOLING UNIT ASSEMBLY
1. Install the rear cooling unit as shown in the illustration.
2. Install the 4 bolts.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
3. Connect the 2 connectors.
INSTALL REAR ROOF NO. 1 AIR DUCT
1. Install the duct with the clip.
2. Attach the 2 claws to install the cooler plate.
CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
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 the 2 O-rings to the air conditioner tube and accessory assembly.
4. Connect the air conditioner tube and accessory assembly.
5. Install the 2 nuts.
  
  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 clips and slide the 2 clips.
INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH
Tech Tips

When installing the front quarter trim panel, operate the reclining adjuster release handle and move the No. 1 rear seat to the position shown in the illustration.
1. Connect the thermistor connector.
2. Attach the 19 clips and 2 claws to install the quarter trim panel.
3. Install the clip.
4. Install the rear No. 2 seat belt anchor with the bolt.
  
  Torque:
  
  42 N*m { 428 kgf*cm, 31 ft.*lbf }
  
  Note
  
  Do not overlap the anchor part of the seat belt and protruding parts of the vehicle body.
5. Install the rear No. 1 seat belt anchor with the bolt.
  
  Torque:
  
  42 N*m { 428 kgf*cm, 31 ft.*lbf }
6. Attach the 3 claws to install the cover.
INSTALL REAR DOOR SCUFF PLATE LH
1. w/o Illumination Type Front Door Scuff Plate:
  1. Attach the 3 claws and 4 clips to install the scuff plate.
  2. Install the screw.
2. w/ Illumination Type Front Door Scuff Plate:
  1. Attach the 3 claws and 4 clips to install the scuff plate.
  2. Install the screw.
INSTALL REAR STEP COVER
Tech Tips

Use the same procedure to install the step cover on the other side.
1. w/o Illumination Type Front Door Scuff Plate:
  
  Attach the 2 claws to install the step cover.
2. w/ Illumination Type Front Door Scuff Plate:
  
  Attach the 4 claws to install the step cover.
INSTALL REAR FLOOR MAT REAR SUPPORT PLATE
1. Attach the 6 clips and 4 claws to install the support plate.
INSTALL REAR NO. 2 SEAT ASSEMBLY LH

Click here
INSTALL REAR NO. 2 SEAT ASSEMBLY RH

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD ENGINE COOLANT
1. for 1UR-FE:
  
  Click here
2. for 3UR-FE:
  
  Click here

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 LEAKS
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.
CHECK SRS WARNING LIGHT

Click here
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.