AIR CONDITIONING UNIT (for Manual 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 ASSEMBLY

    A00OKL4

    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.

      A00OIWCE02
      Text in Illustration
      *1 for Manual Transaxle *2 w/ PTC Heater
      *3 24 N*m (245 kgf*cm, 18 ft.*lbf) *4 9.8 N*m (100 kgf*cm, 87 in.*lbf)

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

    A00ONPEE01

    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 clamps.

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

    A00OHQRE01

    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)

    A00OHSD

    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

    A00OM1J

    1. Install the brace with the 2 bolts.

  8. INSTALL AIR DUCT ASSEMBLY

    A00ONEV

    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. A00ON3M

      Attach the 4 claws to install the defroster nozzle assembly.

  10. 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.

  11. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

    A00OKAN

    1. Attach the 2 claws to install the No. 2 air duct sub-assembly.

  12. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

    A00ON3E

    1. Attach the 2 claws to install the No. 1 air duct sub-assembly.

  13. INSTALL REAR NO. 1 AIR DUCT

    A00OJEJ

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

  14. INSTALL REAR NO. 2 AIR DUCT

    A00ONJQ

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

    2. A00OLLP

      Install the floor carpet with the clip.

  15. INSTALL REAR NO. 3 AIR DUCT

    A00OIJL

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

    2. A00OJXM

      Install the floor carpet with the clip.

  16. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the lower instrument panel Click here.

  17. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Install the upper instrument panel Click here.

  18. CONNECT HEATER WATER INLET HOSE

    A00OHVX

    1. Connect the heater water inlet hose.

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

  19. CONNECT HEATER WATER OUTLET HOSE

    A00OIPI

    1. Connect the heater water outlet hose.

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

  20. CONNECT AIR CONDITIONING TUBE ASSEMBLY


    1. A00OHWY

      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 }

  21. INSTALL COWL TOP OUTER PANEL

    A010HPX

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

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

  22. INSTALL FRONT WIPER MOTOR AND BRACKET


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

  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  24. CHECK SRS WARNING LIGHT


    1. Check the SRS warning light Click here.

  25. ADD ENGINE COOLANT


    1. for 1ZR-FAE:

      Add engine coolant Click here.

    2. for 2ZR-FAE:

      Add engine coolant Click here.

    3. for 3ZR-FAE:

      Add engine coolant Click here.

  26. 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.

  27. 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.

  28. INSPECT FOR COOLANT LEAK


    1. for 1ZR-FAE:

      Inspect for engine coolant leak Click here.

    2. for 2ZR-FAE:

      Inspect for engine coolant leak Click here.

    3. for 3ZR-FAE:

      Inspect for engine coolant leak Click here.

  29. 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.

  30. INSTALL NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)


    1. A00OL2M

      Install the under cover with the 3 clips.

  31. INSTALL NO. 1 ENGINE UNDER COVER


    1. A00ON3U

      Install the under cover with the 10 clips.

  32. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A00OI9A

      Install the front lower bumper absorber with the 3 screws and 8 bolts.

    2. A00OL3A

      Install the 4 screws and 2 bolts.

  33. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A00OKW2

      Install the radiator support opening cover with the 7 clips.

  34. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A00OIJQ

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.