AIR CONDITIONING UNIT (for Automatic Air Conditioning System) INSTALLATION

Tech Tips


  • Use the same procedure for LHD and RHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.


  1. INSTALL AIR CONDITIONING UNIT

    A00OUMN

    1. Install the air conditioning unit with the nut and bolt.

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

    2. Connect the drain cooler hose.

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Install the instrument panel reinforcement.


      1. Install the instrument panel reinforcement with the bolts and screws.

    2. Attach the clamps and connectors to attach the wire harness.

      A00OVPXE11
      Text in Illustration
      *1 w/ PTC Heater *3 9.8 N*m (100 kgf*cm, 87 in.*lbf)
      *2 24 N*m (245 kgf*cm, 18 ft.*lbf) *4 for Manual Transaxle

  3. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

    A00OSC3E01

    1. Install the brace with the 2 bolts and nut.

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

    2. Attach the 4 clamps.

  4. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

    A00OQMRE01

    1. Install the brace with the 2 bolts and nut.

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

    2. Attach the clamp.

  5. INSTALL MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY)

    A00OSPC

    1. Install the main body ECU with the 2 bolts.

    2. Connect the 3 connectors.

  6. INSTALL POWER STEERING ECU ASSEMBLY


    1. for LHD:

      Install the power steering ECU assembly Click here.

    2. for RHD:

      Install the power steering ECU assembly Click here.

  7. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE

    A00OS4N

    1. Install the brace with the 2 bolts.

  8. INSTALL AIR DUCT ASSEMBLY

    A00ORIE

    1. Install the duct with the 2 nuts.

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

  9. INSTALL DEFROSTER NOZZLE ASSEMBLY


    1. A00OQIW

      Attach the 4 claws to install the defroster nozzle assembly.

  10. INSTALL COOLER (SOLAR SENSOR) THERMISTOR

    A003E2I

    1. Disconnect the connector.

    2. Detach the 2 claws and remove the sensor.

  11. INSTALL STEERING COLUMN ASSEMBLY


    1. for Manual Tilt and Manual Telescopic Steering Column:

      Install the steering column Click here.

    2. for Power Tilt and Power Telescopic Steering Column:

      Install the steering column Click here.

  12. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

    A00OUOP

    1. Attach the 2 claws to install the duct.

  13. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

    A00OQZ3

    1. Attach the 2 claws to install the duct.

  14. INSTALL REAR NO. 1 AIR DUCT

    A00OVWQ

    1. Attach the 4 claws to install the rear No. 1 air duct.

  15. INSTALL REAR NO. 2 AIR DUCT

    A00OUN4

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

    2. A00OU14

      Install the floor carpet with the clip.

  16. INSTALL REAR NO. 3 AIR DUCT

    A00OV1D

    1. Attach the 2 claws to install the rear No. 3 air duct.

    2. A00OVCB

      Install the floor carpet with the clip.

  17. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the lower instrument panel Click here.

  18. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the upper instrument panel Click here.

  19. CONNECT HEATER WATER INLET HOSE

    A00OVIW

    1. Connect the heater water inlet hose.

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

  20. CONNECT HEATER WATER OUTLET HOSE

    A00OVBW

    1. Connect the heater water outlet hose.

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

  21. CONNECT AIR CONDITIONING TUBE ASSEMBLY


    1. A00ORA7

      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 }

  22. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the outer cowl top panel with the 9 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Attach the clamp and connect the connector.

  23. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)


    1. A003AJ5E01

      Connect the 2 vacuum hoses.

      Note

      Connect the vacuum hoses so that the painted marks of the 2 vacuum hoses are as shown in the illustration.

    2. A003ASH

      Install the sensor with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Connect the sensor connector and attach the wire harness clamp.

  24. INSTALL FRONT WIPER MOTOR AND BRACKET


    1. Install the front wiper motor and bracket Click here.

  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  26. CHECK SRS WARNING LIGHT


    1. Check the SRS warning light Click here.

  27. ADD ENGINE COOLANT


    1. for 1AD-FTV:

      Add engine coolant Click here.

    2. for 2AD-FHV:

      Add engine coolant Click here.

    3. for 2AD-FTV:

      Add engine coolant Click here.

  28. 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
      440 +/-30 g (15.5 +/-1.1 oz)
      A00DTEOE26

      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.

  29. 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.

  30. INSPECT FOR COOLANT LEAK


    1. for 1AD-FTV:

      Inspect for engine coolant leak Click here.

    2. for 2AD-FHV:

      Inspect for engine coolant leak Click here.

    3. for 2AD-FTV:

      Inspect for engine coolant leak Click here.

  31. 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 observing the following instructions:


      • 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.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A00DTQYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

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

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

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.

  32. INSTALL NO. 1 ENGINE COVER


    1. Attach the 4 clips to install the No. 1 engine cover.

  33. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Insert the 2 hooks of the front lower bumper absorber into the installation holes on the body to install the front lower bumper absorber.

    2. Install the 8 bolts and 3 screws.

    3. Install the 4 screws and 2 bolts.

  34. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Install the radiator support opening cover with the 7 clips.

  35. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the engine under cover with the 11 clips.