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.

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PROCEDURE

  1. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

    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

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  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

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

  7. INSTALL BLOWER ASSEMBLY

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  8. 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.

  9. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

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

      E270981C02

    2. Temporarily install the 3 bolts <B>.

  10. 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.

  11. 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.

  12. INSTALL INSTRUMENT PANEL WIRE

    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. Connect the 2 PTC heater connectors.

  13. INSTALL AIR CONDITIONER UNIT ASSEMBLY

    1. Tighten the 4 bolts, 2 screws and nut.

      E269762C01

      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.

  14. INSTALL NO. 1 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.

  15. 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.

  16. 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.

  17. INSTALL AIR DUCT ASSEMBLY

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

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  18. INSTALL REAR NO. 1 AIR DUCT

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

  19. INSTALL STEERING COLUMN ASSEMBLY

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  20. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

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  21. CONNECT HEATER WATER HOSE

    1. E333896C01

      *a

      View A

      *b

      Heater Water Outlet Hose Paint Mark (Yellow)

      *c

      Heater Water Inlet Hose Paint Mark (Yellow)

      *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.

      Note:

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

  22. CONNECT AIR CONDITIONING TUBE

    1. E333897

      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 11 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

  23. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

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

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  24. INSTALL DECK BOARD ASSEMBLY

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  25. ADD ENGINE COOLANT

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  26. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    1. for HFC-134a(R134a):

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    2. for HFO-1234yf(R1234yf):

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  27. WARM UP COMPRESSOR

    1. for HFC-134a(R134a):

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    2. for HFO-1234yf(R1234yf):

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  28. INSPECT FOR COOLANT LEAK

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  29. INSPECT FOR REFRIGERANT LEAK

    1. for HFC-134a(R134a):

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    2. for HFO-1234yf(R1234yf):

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  30. INITIALIZATION SERVO MOTOR

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