AIR CONDITIONING UNIT INSTALLATION

PROCEDURE

  1. INSTALL AIR CONDITIONING HARNESS ASSEMBLY

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

      E265969C01

      *A

      for Dual Type

      -

      -

    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

    1. Temporarily install the air conditioning amplifier assembly as shown in the illustration.

      E265972

    2. Install the air conditioning amplifier assembly with the screw.

    3. Connect the connector.

  4. INSTALL CONSOLE MOUNTING BRACKET RH

    1. Engage 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 ASPIRATOR PIPE (w/o Cooler System)

    1. Engage the 2 claws to install the aspirator pipe.

  7. INSTALL ASPIRATOR (w/ Cooler System)

    1. Engage the 2 claws to install the aspirator.

  8. INSTALL HEATER COVER (except Cold Area)

    1. Engage the 4 claws to install the heater cover.

  9. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY

    1. Install the air conditioning radiator assembly with the 3 screws.

    2. Connect the connector.

    3. for Cold Area:

      1. Engage each clamp.

      2. Connect the wire harness with the screw.

  10. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY

    1. Engage 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.

  11. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

    1. Engage 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.

  12. 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.

    2. Connect the drain cooler hose.

  13. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

    1. Install the instrument panel reinforcement assembly with the 5 bolts <A>.

      E265936C01
      V100135

      Bolt <A>

      		 V100136

      Bolt <B>

    2. Temporarily install the 3 bolts <B>.

  14. 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. E265933

      Install the front floor carpet assembly to the original position as shown in the illustration.

    3. Install the clip.

  15. 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. E265930

      Install the front floor carpet assembly to the original position as shown in the illustration.

    3. Install the clip.

  16. INSTALL INSTRUMENT PANEL WIRE (for LHD)

    1. Engage each clamp.

      E265926C01

      *A

      w/ ECU Integration Box RH:

      -

      -

      *a

      Ground Portion of the Wiring Harness Protector Cover

      *b

      Earth Wire

      *c

      Guide

      *d

      Clamp
      V100135

      Bolt <A>

      		 V100136

      Bolt <B>
      V100137

      Bolt <C>

      		 V100138

      Connector

    2. Connect each connector.

    3. w/ ECU Integration Box RH:

      1. Engage the guide to connect the ECU integration box RH.

      2. Install the 3 bolts <C>.

        12 N*m

        122 kgf*cm

        9 ft.*lbf

    4. Connect the instrument panel wire with the 5 bolts <B>.

    5. Connect the ground portion of the wiring harness protector cover and earth wire with the 2 bolts <A>.

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

    6. for Cold Area:

      1. Connect the 2 connectors.

  17. INSTALL INSTRUMENT PANEL WIRE (for RHD)

    1. Engage each clamp.

      E266062C01

      *A

      w/ ECU Integration Box RH:

      -

      -

      *a

      Ground Portion of the Wiring Harness Protector Cover

      *b

      Earth Wire

      *c

      Guide

      *d

      Clamp
      V100135

      Bolt <A>

      		 V100136

      Bolt <B>
      V100137

      Bolt <C>

      		 V100138

      Connector

    2. Connect each connector.

    3. w/ ECU Integration Box RH:

      1. Engage the guide to connect the ECU integration box RH.

      2. Install the 3 bolts <C>.

        12 N*m

        122 kgf*cm

        9 ft.*lbf

    4. Connect the instrument panel wire with the 4 bolts <B>.

    5. Connect the ground portion of the wiring harness protector cover and earth wire with the 2 bolts <A>.

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

    6. for Cold Area:

      1. Connect the 2 connectors.

  18. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY (for LHD)

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

      E265973C01
      V100135

      Bolt

      		 V100136

      Screw
      V100137

      Nut

      -

      -

      Bolt, Nut

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

      Screw

      4.0 N*m

      41 kgf*cm

      35 in.*lbf

      Note:

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

  19. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY (for RHD)

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

      E261328C02
      V100135

      Bolt

      		 V100136

      Screw
      V100137

      Nut

      -

      -

      Bolt, Nut

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

      Screw

      4.0 N*m

      41 kgf*cm

      35 in.*lbf

      Note:

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

  20. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE

    1. Install the center instrument panel to cowl brace with the 2 bolts.

  21. INSTALL DEFROSTER NOZZLE ASSEMBLY

    1. Engage the 6 claws to install the defroster nozzle assembly.

  22. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (w/ Cooler System)

    1. Connect the connector and aspirator to install the cooler (room temp. sensor) thermistor.

  23. INSTALL REAR NO. 1 AIR DUCT (for Cold Area)

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

  24. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for LHD)

    Click here

  25. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU (for RHD)

    Click here

  26. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  27. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  28. CONNECT HEATER WATER INLET HOSE A

    1. E265974C01

      *a

      View A

      *b

      Marking (White)

      *c

      Clip Installation Angle (270°)

      Connect the heater water inlet hose A with the marking (white) facing up and engage the clip within the area shown in the illustration.

      Note:

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

  29. CONNECT HEATER WATER OUTLET HOSE A

    1. E265975C01

      *a

      View A

      *b

      Marking (white)

      *c

      Clip Installation Angle (270°)

      Connect the heater water outlet hose A with the marking (white) facing up and engage the clip within the area shown in the illustration.

      Note:

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

  30. INSTALL COOLER CAP (w/o Cooler System)

    1. Sufficiently apply compressor oil to the 2 O-rings.

      Compressor Oil

      ND-OIL 8 or equivalent

    2. Install the cooler cap with the bolt.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  31. CONNECT AIR CONDITIONER TUBE ASSEMBLY (w/ Cooler System)

    1. Remove the vinyl tape from the air conditioner tube assembly.

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

      Compressor Oil

      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioner tube assembly.

    4. Install the air conditioner tube assembly.

  32. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Cooler System)

    1. Remove the vinyl tape from the suction pipe sub-assembly.

    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 to the suction pipe sub-assembly.

    4. Connect the suction pipe sub-assembly.

    5. E265915

      Rotate the hook connector as shown in the illustration.

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

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  33. INSTALL OUTER COWL TOP PANEL (for 1AD-FTV, 1ND-TV)

    for LHD:Click here

    for RHD:Click here

  34. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for 1AD-FTV)

    Click here

  35. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for 1AD-FTV, 1ND-TV)

    for LHD:Click here

    for RHD:Click here

  36. INSTALL WATER GUARD PLATE LH (for 1AD-FTV, 1ND-TV)

    for LHD:Click here

    for RHD:Click here

  37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (for 1AD-FTV, 1ND-TV)

    Click here

  38. INSPECT FOR COOLANT LEAK (for 1AD-FTV)

    Click here

  39. INSPECT FOR COOLANT LEAK (for 1ND-TV)

    Click here

  40. INSPECT FOR COOLANT LEAK (for 1NR-FE)

    Click here

  41. INSPECT FOR COOLANT LEAK (for 1ZR-FAE)

    Click here

  42. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1AD-FTV)

    Click here

  43. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1ND-TV)

    Click here

  44. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1NR-FE)

    Click here

  45. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL (for 1ZR-FAE)

    Click here

  46. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Cooler System)

    Click here

  47. WARM UP ENGINE (w/ Cooler System)

    Click here

  48. INSPECT FOR REFRIGERANT LEAK (w/ Cooler System)

    Click here

  49. INITIALIZE SERVO MOTOR

    Click here