AIR CONDITIONING UNIT (for Manual Air Conditioning System) INSTALLATION

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.


  1. INSTALL NO. 3 AIR DUCT


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

  2. TEMPORARILY INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Temporarily install the air conditioning unit with the bolt and nut.

      Note


      • Be sure to support the air conditioning unit assembly when installing it, because failure to do so may cause the bracket of the air conditioning unit assembly to break.

      • When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.

  3. INSTALL NO. 1 COOLER UNIT DRAIN HOSE


    1. Install the No. 1 cooler unit drain hose.

  4. INSTALL INSTRUMENT PANEL REINFORCEMENT


    1. for Manual Transmission:

      Install the instrument panel reinforcement with the 8 bolts.

      Torque:
      for bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. for Automatic Transmission:

      Install the instrument panel reinforcement with the 7 bolts.

      Torque:
      for bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      A01DUXEE02
      Text in Illustration
      *A for Manual Transmission - -
      *1 Bolt A *2 Bolt B

    3. Temporarily install the 3 bolts.

      A01DYZX

    4. Connect the connectors.

    5. Attach the 12 clamps.

    6. Install the grommet to the vehicle body.

    7. Connect the ground wires to the instrument panel reinforcement with the 2 bolts.

    8. w/o PTC Heater:

      Connect the 2 connectors and attach the 2 clamps.

    9. w/ PTC Heater:

      Connect the 4 connectors and attach the 2 clamps.

    10. Connect the connector and attach the 3 clamps.

  5. INSTALL ECM


    1. for 1GR-FE:

      Click here

    2. for 1TR-FE:

      Click here

    3. for 2TR-FE:

      Click here

    4. for 1KD-FTV:

      Click here

    5. for 1KD-FTV, for DPF:

      Click here

    6. for 2KD-FTV:

      Click here

    7. for 2KD-FTV, for DPF:

      Click here

    8. for 5L-E:

      Click here

  6. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      A01E0DFE01
    2. A01E0M7

      Temporarily install the screw.

    3. A01E0E4E01

      Tighten the bolt and nut in the order shown in the illustration.

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

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


    1. Install the driver side junction block with the 2 nuts.

    2. Connect the connectors.

    3. Attach the 2 clamps.

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    5. A01E0M7

      Tighten the screw.

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

  8. INSTALL NO. 4 AIR DUCT


    1. Attach the 2 claws to install the No. 4 air duct.

  9. INSTALL NO. 2 AIR DUCT


    1. Attach the 2 claws to install the No. 2 air duct.

  10. INSTALL NO. 1 AIR DUCT


    1. Attach the 2 claws to install the No. 1 air duct.

  11. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  12. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  13. INSTALL DEFROSTER NOZZLE ASSEMBLY (w/ Defroster)


    1. Attach the 4 clips to install the defroster nozzle assembly.

  14. INSTALL NO. 3 HEATER TO REGISTER DUCT


    1. Attach the 4 clips to install the defroster nozzle assembly.

    2. Install the clip.

  15. INSTALL NO. 1 HEATER TO REGISTER DUCT


    1. Attach the 3 claws to install the No. 1 heater to register duct.

    2. Install the clip.

  16. INSTALL NO. 2 HEATER TO REGISTER DUCT


    1. Install the No. 2 heater to register duct with the 3 clips.

  17. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY

    Click here

  18. CONNECT HEATER WATER OUTLET HOSE


    1. A01DYIWE02
      Text in Illustration
      *a Acceptable Range
      *b 2 to 40°

      Connect the heater water outlet hose and connect the clip.

  19. CONNECT HEATER WATER INLET HOSE


    1. A01E0LWE02
      Text in Illustration
      *a Acceptable Range
      *b 2 to 40°

      Connect the heater water inlet hose and connect the clip.

  20. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape attached to the air conditioning tube and accessory assembly.

    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 to the air conditioning tube and accessory assembly.

    4. Connect the air conditioning tube and accessory assembly.

  21. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape attached to the suction hose sub-assembly.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.

    4. Connect the suction tube and attach the piping clamp.

      Tech Tips

      After the connection, check that the claw of the piping clamp is attached.

    5. Install the bolt.

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

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  23. ADD ENGINE COOLANT


    1. for 1GR-FE:

      Click here

    2. for 1KD-FTV (w/ EGR Cooler):

      Click here

    3. for 1KD-FTV (w/o EGR Cooler):

      Click here

    4. for 2KD-FTV (w/ EGR Cooler):

      Click here

    5. for 2KD-FTV (w/o EGR Cooler):

      Click here

    6. for 1TR-FE:

      Click here

    7. for 2TR-FE:

      Click here

    8. for 5L-E:

      Click here

  24. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      450 +- 30 g (15.87 +- 1.05 oz.)
      A01DWS4E02

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.


      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

  25. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      Note

      After removing and installing the cooler refrigerant lines (with the compressor), be sure to warm up the compressor when turning the A/C switch ON. This is done to prevent damage to the compressor.

  26. CHECK FOR ENGINE COOLANT LEAKS


    1. for 1GR-FE:

      Click here

    2. for 1KD-FTV (w/ EGR Cooler):

      Click here

    3. for 1KD-FTV (w/o EGR Cooler):

      Click here

    4. for 2KD-FTV (w/ EGR Cooler):

      Click here

    5. for 2KD-FTV (w/o EGR Cooler):

      Click here

    6. for 1TR-FE:

      Click here

    7. for 2TR-FE:

      Click here

    8. for 5L-E:

      Click here

  27. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met.


      • The ignition switch is OFF.

      • The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up.

      • Some refrigerant is remaining in the refrigerant system.

      • The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2).

    2. A01DWJCE03

      Check for refrigerant gas leakage from the refrigerant line.


      1. After the blower motor stops, wait at least 15 minutes.

      2. Using a gas leak detector, check that gas is not leaking from the refrigerant line. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    3. Check for refrigerant gas leakage from the cooling unit.


      1. Hold the gas leak detector so that the sensor is under the drain hose, as shown in the illustration.

      2. Check that gas is not leaking from the drain hose. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    4. Check for refrigerant gas leakage from the cooling unit.


      1. Remove the blower motor control from the unit. Insert the gas leak detector's sensor into the unit.

      2. Check that gas is not leaking from the unit. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    5. Check for refrigerant gas leakage from the pressure switch.


      1. Disconnect the pressure switch connector and wait approximately 20 minutes.

      2. Using a gas leak detector, check that gas is not leaking from the pressure switch. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    6. Repeat all steps above 2 to 3 times.

  28. CHECK SRS WARNING LIGHT

    Click here