AIR CONDITIONING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Install the air conditioning unit assembly with the 3 bolts in the order shown in the illustration.

      A019JWYE01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.

  2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A019K0R

      Engage the 4 claws to install the No. 1 air duct sub-assembly.

  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY


    1. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 5 "TORX" bolts in the order shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.

    2. Install the 5 instrument panel safety pad caps.

      A019MXAE03
      Text in Illustration
      *1 Instrument panel safety pad cap *2 "TORX" bolt

    3. Install the 2 bolts and 2 caps to engine compartment side.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Install the instrument panel reinforcement assembly with air conditioning unit assembly with the nut.

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

    5. Connect the cooler drain hose as shown in the illustration.

      Note

      Connect the cooler drain hose firmly to prevent water leaks.

      A019OI0E01
      Text in Illustration
      *1 Cap *2 Bolt
      *3 Nut *4 Cooler drain hose

    6. Engage each clamp.

    7. Install the bolt and connect the earth wire.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Connect the connector holder with the nut.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    9. Connect the connector.

    10. Connect the blower motor connector.

    11. Connect the 2 air conditioning ECU connectors.

      A019LNKE01
      Text in Illustration
      *1 Blower motor connector *2 Air conditioning ECU connector
      *3 Nut *4 Connector holder
      *5 Bolt *6 Earth wire

    12. Engage each clamp.

    13. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    14. Connect each connector.

      A019PK6E01
      Text in Illustration
      *1 Bolt *2 Earth wire

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


    1. A019PDYE01
      Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut

      Install the 2 bolts and 2 nuts.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Install the No. 2 instrument panel brace sub-assembly with the screw.

    3. Engage each clamp.

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


    1. A019PB6E01
      Text in Illustration
      *1 Screw
      *2 Bolt
      *3 Nut

      Install the 2 bolts and 2 nuts.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Install the No. 1 instrument panel brace sub-assembly with the screw.

    3. Engage each clamp.

  6. INSTALL NO. 5 INSTRUMENT PANEL BRACKET


    1. A019L15

      Install the 2 No. 5 instrument panel brackets.

  7. INSTALL CENTER HEATER TO REGISTER SUB DUCT


    1. A019O22

      Install the center heater to register sub duct with the 3 clips.

  8. INSTALL REAR NO. 3 AIR DUCT


    1. A019OHP

      Engage the 2 claws to install the rear No. 3 air duct.

  9. INSTALL REAR NO. 4 AIR DUCT


    1. A019NF3

      Engage the claw to install the rear No. 4 air duct.

    2. Install the clip.

    3. A019KWYE01

      Engage the claw and 2 clamps.

    4. Engage the fastener to install the floor carpet to the original position.

      Text in Illustration
      *1 Clamp
      *2 Fastener

  10. INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. A019MX6

      Engage the guide as shown in the illustration.

    2. A019KIU

      Engage the claw to install the frame number cover.

  11. INSTALL REAR NO. 1 AIR DUCT


    1. A019O53

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

    2. Engage the clamp.

  12. INSTALL REAR NO. 2 AIR DUCT


    1. A019K5X

      Engage the claw to install the rear No. 2 air duct.

    2. Install the clip.

    3. A019MUPE01

      Engage the claw and 2 clamps.

    4. Engage the fastener to install the floor carpet to the original position.

      Text in Illustration
      *1 Clamp
      *2 Fastener

  13. INSTALL ECU INTEGRATION BOX


    1. Install the ECU integration box with the bolt and 2 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  14. INSTALL CLEARANCE WARNING BUZZER


    1. Engage the clamp to install the clearance warning buzzer.

    2. Connect the connector.

  15. INSTALL TURN SIGNAL FLASHER ASSEMBLY


    1. A019NEI

      Connect the connector.

    2. Engage the clamp to install the turn signal flasher assembly.

  16. INSTALL POWER STEERING ECU ASSEMBLY

    for LHD Click here

    for RHD Click here

  17. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for LHD)


    1. A019NDA

      Engage the claw to connect the connector as shown in the illustration.

    2. A019O4R

      Engage the 2 claws to lock the connector lock as shown in the illustration.

    3. A019NAD

      Engage the claw to connect the connector as shown in the illustration.

    4. Install the instrument panel junction block assembly with the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A019K87E01

      Connect the 4 connectors (A).

    6. Engage the 2 claws to connect the 2 connectors (B).

    7. Connect the 2 connectors.

  18. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY (for RHD)


    1. A019NDA

      Engage the claw to connect the connector as shown in the illustration.

    2. A019O4R

      Engage the 2 claws to lock the connector lock as shown in the illustration.

    3. A019MIT

      Engage the claw to connect the connector as shown in the illustration.

    4. Install the instrument panel junction block assembly with the bolt and nut.

      Torque:
      Bolt
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A019P1IE01

      Connect the connector (A).

    6. Engage the 2 claws to connect the 2 connectors (B) as shown in the illustration.

    7. Connect the 3 connectors.

  19. INSTALL STEERING POST ASSEMBLY

    Click here

  20. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

    Click here

  21. CONNECT INLET HEATER WATER HOSE


    1. A019M1Y

      Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.

  22. CONNECT OUTLET HEATER WATER HOSE


    1. A019PLP

      Using pliers, grip the claws of the clip and slide the clip to connect the outlet heater water hose.

  23. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the pipe.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the air conditioning tube and accessory assembly.

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the air conditioning tube and accessory assembly.

  24. CONNECT SUCTION PIPE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the pipe.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the suction pipe sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

    4. Install the suction pipe sub-assembly.

    5. A019OXF

      Move the hook connector in the direction indicated by the arrow in the illustration.

    6. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    7. A019OF9

      Engage the 6 clamps to the engine wire harness.

  25. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD Click here

    for RHD Click here

  26. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension)


    1. A019N7O

      Install the front shock absorber cap with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  27. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

    Tech Tips

    Use the same procedure for the RH side and LH side.

  28. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A019K93

      Install the windshield wiper motor and link assembly with the 5 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      Be careful not to damage the windshield when installing the windshield wiper motor and link assembly.

    2. A019NAG

      w/o Deicer:


      1. Engage the clamp.

      2. Connect the connector.

    3. A019JXV

      w/ Deicer:


      1. Engage the clamp.

      2. Connect each connector.

  29. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Engage the 10 guides.

      A019KO1E01

    2. Engage the 6 claws and guide <A> as shown in the illustration.

    3. Install the 2 clips to cowl top ventilator louver sub-assembly.

  30. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A019LY2E06
      Text in Illustration
      *1 Wiper Arm Serration
      *2 Wire Brush
      *3 Wiper Pivot Serration

      When reusing the front wiper arm and blade assembly RH:


      1. Clean the wiper arm serrations.

    3. When reusing the windshield wiper link assembly:


      1. Clean the wiper pivot serrations with a wire brush.

    4. A019PK0E01
      Text in Illustration
      *1 Ceramic Dot

      Install the front wiper arm and blade assembly RH with the 2 nuts to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      While holding the tip of the wiper blade on the glass at approximately 20 mm above the ceramic dot, press down on the wiper arm and tighten the nut. Then raise and lower the wiper arm a few times to confirm that it has settled to the specified position.

  31. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A019LY2E05
      Text in Illustration
      *1 Wiper Arm Serration
      *2 Wire Brush
      *3 Wiper Pivot Serration

      When reusing the front wiper arm and blade assembly LH:


      1. Clean the wiper arm serrations.

    2. When reusing the windshield wiper link assembly:


      1. Clean the wiper pivot serrations with a wire brush.

    3. A019LK0E01
      Text in Illustration
      *1 Ceramic Dot

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the wiper arm by hand while tightening the nut.

    4. Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

  32. INSTALL FRONT WIPER ARM HEAD CAP


    1. A019O2C

      Engage the 3 claws to install the front wiper arm head cap.

  33. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  34. INSTALL FRONT FENDER TO COWL SIDE SEAL LH


    1. Wipe off any tape adhesive residue with cleaner.

    2. A019KT9E01
      Text in Illustration
      *1 Double-Sided Tape

      Engage the 2 claws and install a new front fender to cowl side seal LH.

  35. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  36. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH


    1. A019O73

      Engage the 3 clips and 2 guides.

    2. Install the front fender top reinforcement sub-assembly LH with the clip.

    3. A019ND4E01
      Text in Illustration
      *1 Hood to Cowl Top Seal

      Engage the clip to the hood to cowl top seal to the front fender top reinforcement sub-assembly LH.

  37. INSTALL FRONT SEAT ASSEMBLY


    1. for LH Side: Click here

    2. for RH Side:

      Tech Tips

      Use the same procedure for the RH side and LH side.

  38. ADD ENGINE COOLANT

    for 2GR-FE: Click here

    for 1AR-FE: Click here

  39. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A019MUNE05
      Standard (for Suction Pipe Separate Type)
      450 to 550 g (15.9 to 19.4 oz.)
      Standard (except Suction Pipe Separate Type)
      500 to 600 g (17.6 to 21.2 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

  40. WARM UP ENGINE


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      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.

  41. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Turn the engine switch off.

      • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A019KMKE31
      Text in Illustration
      *1 Inspect for Leak
      *2 Halogen Leak Detector

      Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

    4. A019MG9E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the halogen leak detector sensor under the drain hose.

      • When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

    5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

  42. INSPECT FOR COOLANT LEAK

    for 2GR-FE: Click here

    for 1AR-FE: Click here

  43. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 6 clips.

  44. INSTALL ENGINE ROOM SIDE COVER


    1. Engage the guide.

    2. Install the engine room side cover with the 4 clips.

  45. INSTALL ENGINE ROOM SIDE COVER LH


    1. Engage the guide.

    2. Install the engine room side cover LH with the 4 clips.

  46. INITIALIZE SERVO MOTOR


    1. Turn the engine switch off.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the engine switch on (IG).

    4. Press the A/C OFF switch.

    5. Turn the intelligent tester on.

    6. Enter the following menus: Body / Air Conditioner / Utility / Servomotor Initialization.

    7. According to the intelligent tester display, select the "Next" switch.

    8. According to the intelligent tester display, select the "Next" switch.

      Tech Tips

      During initialization, the AUTO indicator illuminates. When initialization is complete, the indicator turns off.

    9. According to the intelligent tester display, select the exit to finish the initialization.