AIR CONDITIONING UNIT INSTALLATION

CAUTION / NOTICE / HINT

Tip:

  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

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

    Click here

PROCEDURE

  1. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)

    1. Route the air conditioning harness assembly as shown in the illustration.

      E260966

    2. Connect each connector.

    3. Engage each clamp to install the air conditioning harness assembly.

  2. INSTALL DRAIN COOLER HOSE

    1. E265970C01

      *a

      Hose Notch

      *b

      Rib

      Align the hose notch and rib as shown in the illustration and install the drain cooler hose.

  3. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  4. INSTALL CONSOLE MOUNTING BRACKET RH

    1. Attach the 2 claws to install the console mounting bracket RH.

  5. INSTALL CONSOLE MOUNTING BRACKET LH

    1. Install the console mounting bracket LH with the screw.

  6. INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY (for Automatic Air Conditioning System)

    1. Engage the 2 claws to install the air conditioning duct sub-assembly.

  7. INSTALL SKID CONTROL BUZZER ASSEMBLY (for RHD)

    Click here

  8. INSTALL BLOWER ASSEMBLY

    Click here

  9. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

    1. Temporarily install the air conditioner unit assembly with the bolt and nut.

      Note:

      To prevent damage to the installation bracket for the air conditioner unit assembly, be sure to support the air conditioner unit assembly in place.

    2. Connect the drain cooler hose.

  10. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

    1. Install the instrument panel reinforcement assembly with the 6 bolts <A>.

      E270981N01

    2. Temporarily install the 3 bolts <B>.

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

    1. Install the No. 2 instrument panel brace sub-assembly with the bolt, screw and nut.

      Tip:

      Do not fully tighten the screw.

    2. Install the front floor carpet assembly to the original position and install the clip.

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

    1. Install the No. 1 instrument panel brace sub-assembly with the bolt, screw and nut.

      Tip:

      Do not fully tighten the screw.

    2. Install the front floor carpet assembly to the original position and install the clip.

  13. INSTALL INSTRUMENT PANEL WIRE (for LHD)

    1. Attach each clamp.

      E269765C01

      *1

      ECU Integration Box RH

      *2

      Instrument Panel Junction Block Assembly

    2. Connect each connector.

    3. Connect the ECU integration box RH with the 2 nuts and bolt.

      for Nut

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

      for Bolt

      12 N*m

      122 kgf*cm

      9 ft.*lbf

    4. Connect the instrument panel junction block assembly with the 2 bolts.

      3.2 N*m

      33 kgf*cm

      28 in.*lbf

    5. Connect the instrument panel wire with the 2 bolts <A>.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    6. Connect the ground wire with the 3 bolts.

      for Bolt <B>

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

      for Bolt <C>

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

    7. w/ PTC Heater:

      Connect the 2 or 3 connectors.

  14. INSTALL INSTRUMENT PANEL WIRE (for RHD)

    1. Attach each clamp.

      E270982C01

      *1

      ECU Integration Box RH

      *2

      Instrument Panel Junction Block Assembly

      *3

      Engeine Stop and Start ECU

      -

      -

    2. Connect each connector.

    3. Connect the ECU integration box RH with the 3 bolts.

      for Nut

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

      for Bolt

      12 N*m

      122 kgf*cm

      9 ft.*lbf

    4. Connect the instrument panel junction block assembly with the 2 nuts and bolt.

      for Nut

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

      for Bolt

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    5. Install the engine stop and start ECU with the bolt and nut.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    6. Connect the instrument panel wire with the 3 bolts <A>.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    7. Connect the ground wire with the 3 bolts.

      for Bolt <B>

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

      for Bolt <C>

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

    8. w/ PTC Heater:

      Connect the 2 or 3 connectors.

  15. INSTALL AIR CONDITIONER UNIT ASSEMBLY

    1. for LHD:

      Tighten the 4 bolts, 2 screws and nut.

      E269762N01

      for Bolt

      9.8 N*m

      100 kgf*cm

      7 ft.*lbf

      Note:

      Tighten the bolts, screws and nut in the order shown in the illustration to install the air conditioner unit assembly.

    2. for RHD:

      Tighten the 4 bolts, 2 screws and nut.

      E270983N01

      for Bolt

      9.8 N*m

      100 kgf*cm

      7 ft.*lbf

      Note:

      Tighten the bolts, screws and nut in the order shown in the illustration to install the air conditioner unit assembly.

  16. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

    1. Attach the 2 claws to install the No. 3 air duct sub-assembly.

      Note:

      If any of the claws of the No. 3 air duct sub-assembly are cracked or deformed, make sure to replace the air duct with a new one. Failure to do so may cause the No. 3 air duct sub-assembly to fall off or noise to occur.

  17. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

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

      Note:

      If any of the claws of the No. 2 air duct sub-assembly are cracked or deformed, make sure to replace the air duct with a new one. Failure to do so may cause the No. 2 air duct sub-assembly to fall off or noise to occur.

  18. INSTALL DEFROSTER NOZZLE ASSEMBLY

    1. Attach the 3 hooks to install the defroster nozzle assembly.

    2. Connect the automatic light control sensor (solar sensor) connector and attach the 2 harness clamps.

  19. INSTALL AIR DUCT ASSEMBLY

    1. Install the air duct assembly with the 2 nuts.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  20. INSTALL REAR NO. 1 AIR DUCT

    1. Attach the 8 claws to install the rear No. 1 air duct.

  21. INSTALL STEERING COLUMN ASSEMBLY

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  22. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  23. CONNECT HEATER WATER HOSE

    1. E269763C02

      *a

      View A

      *b

      Heater Water Outlet Hose Paint Mark

      *c

      Heater Water Inlet Hose Paint Mark

      *d

      Clip installation angle (270°)

      Connect the heater water outlet hose A and heater water inlet hose A with the paint mark facing up and attach the clip within the area shown in the illustration.

      Paint Mark Color

      Engine

      Transmission

      Hose

      Color

      2AR

      All

      Outlet

      Purple

      Inlet

      Purple

      3ZR

      Manual Transmission

      Outlet

      Pink

      Inlet

      Pink

      CVT

      Outlet

      Blue

      Inlet

      Blue

      1AD, 2AD

      w/o Fuel Heater

      Outlet

      Blue

      Inlet

      Blue

      w/ Fuel Heater

      Outlet

      Green

      Inlet

      Green

      2WW

      w/o Fuel Heater

      Outlet

      Orange

      Inlet

      Orange

      w/ Fuel Heater

      Outlet

      Orange

      Inlet

      White
      Note:

      Do not apply excessive force to the heater water outlet hose A and heater water inlet hose A.

  24. CONNECT AIR CONDITIONING TUBE

    1. E269764

      Remove the vinyl tape from the suction tube sub-assembly and liquid tube sub-assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the suction tube sub-assembly and liquid tube sub-assembly.

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the suction tube sub-assembly liquid tube sub-assembly.

    4. Connect the liquid tube sub-assembly and suction tube sub-assembly.

    5. Rotate the hook connector in the direction indicated by the arrow in the illustration and install the bolt.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

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  26. INSTALL NO. 3 COWL TOP PANEL INSULATOR (for 2WW)

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  27. INSTALL NO. 1 ENGINE COVER (for 2WW)

    Click here

  28. ADD ENGINE COOLANT

    for 2AD-FHV:Click here

    for 2AD-FTV:Click here

    for 2AR-FE:Click here

    for 3ZR-FAE:Click here

    for 3ZR-FE:Click here

    for 2WW:Click here

  29. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  30. WARM UP ENGINE

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  31. INSPECT FOR COOLANT LEAK

    for 2AD-FHV:Click here

    for 2AD-FTV:Click here

    for 2AR-FE:Click here

    for 3ZR-FAE:Click here

    for 3ZR-FE:Click here

    for 2WW:Click here

  32. INSPECT FOR REFRIGERANT LEAK

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  33. INITIALIZATION SERVO MOTOR (for Automatic Air Conditioning System)

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