AIR CONDITIONING UNIT INSTALLATION

PROCEDURE

INSTALL NO. 2 AIR DUCT
1. Engage the 3 claws and install the air duct.
INSTALL NO. 1 AIR DUCT
1. Engage the 3 claws and install the air duct.
INSTALL COOLER AIR HOSE
1. Install the cooler air hose.
INSTALL AIR CONDITIONING RADIATOR ASSEMBLY
1. Install the air conditioning radiator with the 3 screws.
INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
1. Engage the claw and install the air conditioning amplifier as shown in the illustration.
2. Tighten the screw.
3. Connect the connector.
INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for LHD)
1. Connect the connectors and engage the clamps, then install the air conditioning harness.
INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for RHD)
1. Connect the connectors and engage the clamps, then install the air conditioning harness.
TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY
1. Temporarily tighten the air conditioning unit with the 3 bolts and nut.
  
  Note
  
  To prevent damage to the installation bracket for the air conditioning unit, be sure to support the air conditioning unit in place.
INSTALL INSTRUMENT PANEL REINFORCEMENT
1. Install the instrument panel reinforcement with the 8 bolts.
INSTALL REAR NO. 1 AIR DUCT (for Cold Area Specification Vehicles)
1. Engage the 2 claws and install the rear No. 1 air duct.
INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
1. Install the instrument panel brace with the 2 bolts, nut and screw.
INSTALL AIR CONDITIONER UNIT ASSEMBLY (for LHD)
1. Install the air duct with the 2 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
2. Install the bolt, nut and 4 screws in the order shown in the illustration.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
  
  for bolt
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  
  for nut
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  
  for screw 1, 2, 3
INSTALL AIR CONDITIONER UNIT ASSEMBLY (for RHD)
1. Install the air duct with the 2 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
2. Install the bolt, nut and 4 screws in the order shown in the illustration.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
  
  for bolt
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  
  for nut
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  
  for screw 1, 2, 3
INSTALL INSTRUMENT PANEL WIRE (for LHD)
1. Connect the connectors and engage the clamps, then install the instrument panel wire.
2. Install the ground wire with the bolts.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
3. Engage the clamp and connect the instrument panel wire.
4. Connect the 2 connectors.
5. Engage the 3 clamps and install the connector holders.
6. Install the bolt.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
7. Connect the connectors.
8. Install the connector holder with the screw.
9. Connect the 2 clamps and install the connector holders.
10. Tighten the screw.
11. Connect the connectors.
12. Connect the 2 clamps.
13. for Cold Area Specification Vehicles:
  1. Install the ground wire with the bolt.
    
    Torque:
    
    8.4 N*m { 86 kgf*cm, 74 in.*lbf }
INSTALL INSTRUMENT PANEL WIRE (for RHD)
1. Connect the connectors and engage the clamps, then install the instrument panel wire.
2. Install the ground wire with the bolts.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
3. Engage the 3 clamps and connect the instrument panel wire.
4. Connect the 2 connectors.
5. Engage the 3 clamps and install the connector holders.
6. Install the bolt.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
7. Connect the connectors.
8. Install the connector holder with the screw.
9. Connect the 2 clamps and install the connector holders.
10. Tighten the screw.
11. Connect the connectors.
12. Connect the 2 clamps.
INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY
1. Connect the back side connectors and install the instrument panel junction block as shown in the illustration.
  
  Note
  
  Securely connect the connector.
2. Install the instrument panel junction block with the bolt.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
3. Connect the front side connectors as shown in the illustration.
  
  Note
  
  Securely connect the connector.
4. Engage the clamps.
INSTALL DRAIN COOLER HOSE
1. Text in Illustration
  
  *a UP Mark
  
  Install the drain cooler hose as shown in the illustration.
  Note
  - Install the drain hose with its UP mark facing upward, within the 60 degree range shown in the illustration.
  - Install the drain hose without twisting it.
INSTALL REAR NO. 3 AIR DUCT (for Cold Area Specification Vehicles)
1. Install the 2 claws and install the air duct.
INSTALL REAR NO. 4 AIR DUCT (for Cold Area Specification Vehicles)
1. Install the 2 claws and install the air duct.
INSTALL REAR NO. 2 AIR DUCT (for Cold Area Specification Vehicles)
1. Install the 2 claws and install the air duct.
2. Return the floor carpet.
INSTALL DEFROSTER NOZZLE ASSEMBLY
1. Engage the 2 claws and 3 guides, then install the defroster nozzle.
2. Engage the clamps and connect the connectors, then connect the wire harness.
INSTALL NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System)

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INSTALL HEATER TO REGISTER DUCT ASSEMBLY (w/ Navigation System)
1. Engage the 3 claws and install the heater to register duct.
2. Engage the clamp and connect the wire harness.
INSTALL HEATER TO REGISTER DUCT ASSEMBLY (w/o Navigation System)
1. Engage the 3 claws and install the heater to register duct.
INSTALL STEERING COLUMN ASSEMBLY (for LHD)

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INSTALL STEERING COLUMN ASSEMBLY (for RHD)

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INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

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CONNECT WATER HOSE SUB-ASSEMBLY
1. Text in Illustration
  
  *a View A
  
  *b White Paint Mark
  
  Connect the water hose onto the air conditioning unit.
  
  Tech Tips
  
  Perform the installation with the hose clip and mark at the correct angle.
CONNECT WATER HOSE SUB-ASSEMBLY B
1. Text in Illustration
  
  *a View A
  
  *b Purple Paint Mark
  
  Connect the water hose onto the air conditioning unit.
  
  Tech Tips
  
  Perform the installation with the hose clip and mark at the correct angle.
CONNECT LIQUID TUBE SUB-ASSEMBLY A
1. Remove the vinyl tape from liquid tube and the connecting portion of the unit.
2. Apply sufficient compressor oil (ND-OIL11) to a new O-ring and the connecting part of the liquid tube.
  
  Compressor oil
  
  ND-OIL11 or equivalent
3. Install the O-ring onto the liquid tube.
4. Connect the liquid tube to the unit.
CONNECT SUCTION TUBE SUB-ASSEMBLY B
1. Remove the vinyl tape from suction tube and the connecting portion of the unit.
2. Apply sufficient compressor oil (ND-OIL11) to a new O-ring and the connecting part of the suction tube.
  
  Compressor oil
  
  ND-OIL11 or equivalent
3. Install the O-ring onto the suction tube.
4. Securely connect the suction tube to the air conditioning unit.
5. Turn the hook connector in the direction indicated by the arrow in the illustration.
6. Insert the pipe joints securely into the fitting holes and tighten the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL OUTER COWL TOP PANEL

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INSTALL INNER COWL TOP TO COWL BRACE

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INSTALL FRONT AIR SHUTTER SEAL RH

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INSTALL FRONT NO. 1 VENTILATOR SEAL

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INSTALL WINDSHIELD WIPER MOTOR AND LINK

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CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

Torque:

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

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL FRONT FLOOR COVER RH (for Front Floor Cover Type A)

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INSTALL FRONT FLOOR COVER RH (for Front Floor Cover Type B)

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INSTALL CENTER FRONT FLOOR COVER (for Front Floor Cover Type B)

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ADD ENGINE COOLANT

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CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
INSPECT FOR COOLANT LEAK

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WARM UP COMPRESSOR

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INSPECT FOR REFRIGERANT LEAK

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Text in Illustration
*a	View A
*b	White Paint Mark

Text in Illustration
*a	View A
*b	Purple Paint Mark