AIR CONDITIONING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY


    1. B007UFC

      Install the air conditioning radiator assembly with the 3 screws.

    2. B007S32

      for LHD, w/ PTC:


      1. Install the wire harness with the screw.

    3. for RHD, w/ PTC:


      1. B007TPFE03

        Attach the clamp.

  2. INSTALL AIR DUCT NO.2


    1. B007QVDE01

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

  3. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Install the air conditioner unit assembly with the 3 bolts.

      B007W8S

  4. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Driver seat:


      1. Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 Torx bolts.

    2. Passenger seat:


      1. Using a hexagon wrench 12 mm, install the instrument panel reinforcement assembly with the 2 bolts.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Using a "Torx" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "Torx" bolts.

        B007VO2E02
        Text in Illustration
        *A for Manual Transmission - -
        *1 Collar *2 ''Torx'' Bolt
        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Install the 2 bolts and nut. (AUTOMATIC TRANSMISSION)

    4. Install the 3 bolts and nut. (MANUAL TRANSMISSION)

    5. Install the 2 bolts and cap.

    6. Attach the clamps and connectors.

      B007TC4E01
      *A w/ PTC *B for Wide Body
      *a Ground Wire - -

    7. Install the bolt and nut.

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

  5. INSTALL INSTRUMENT PANEL TO FLOOR BRACE SUB-ASSEMBLY

  6. CONNECT PARKING BRAKE CONTROL HANDLE SUB-ASSEMBLY

  7. INSTALL AIR DUCT NO.1

  8. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  9. INSTALL INSTRUMENT PANEL ASSEMBLY

    Click here

  10. INSTALL HEATER WATER HOSE INLET A

  11. INSTALL HEATER WATER HOSE OUTLET

  12. INSTALL COOLER REFRIGERANT LIQUID PIPE B


    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 cooler refrigerant liquid pipe B.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the cooler refrigerant liquid pipe B.

    4. Install the cooler refrigerant liquid pipe B.

  13. INSTALL COOLER REFRIGERANT SUCTION PIPE A


    1. Remove the attached vinyl tape from the hose.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant suction pipe A.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the cooler refrigerant suction pipe A.

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

    5. B007UD1E01
      Text in Illustration
      *1 Cooler Refrigerant Suction Pipe A
      *2 Hook Connector
      *3 Cooler Refrigerant Liquid

      Insert the pipe joints into the fitting holes securely and tighten the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  14. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. for 1KD-FTV: Click here

    2. for 2KD-FTV: Click here

    3. for 1GD-FTV: Click here

  15. REMOVE NO.1 ENGINE UNDER COVER (w/ Under Cover and Intercooler)

  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    Note

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

  18. ADD ENGINE COOLANT


    1. for 1KD-FTV: Click here

    2. for 2KD-FTV: Click here

    3. for 1TR-FE: Click here

    4. for 2TR-FE: Click here

    5. for 5L-E: Click here

    6. for 1GD-FTV: Click here

  19. CHARGE REFRIGERANT

    Click here

  20. WARM UP ENGINE

    Click here

  21. CHECK FOR ENGINE COOLANT LEAKS


    1. for 1KD-FTV: Click here

    2. for 1TR-FE: Click here

    3. for 1GD-FTV: Click here

  22. INSPECT COOLING SYSTEM


    1. for 2KD-FTV: Click here

    2. for 2TR-FE: Click here

    3. for 5L-E: Click here

  23. CHECK FOR LEAKAGE OF REFRIGERANT

    Click here