AIR CONDITIONING UNIT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • Use the same procedure for the RH and LH sides.

  • The procedure listed below is for the LH side.

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

    Click here

PROCEDURE


  1. INSTALL AIR CONDITIONING UNIT ASSEMBLY


    1. Temporarily install the air conditioner unit assembly with the 3 bolts.

      Note

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

  2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY


    1. Install the instrument panel reinforcement assembly with air conditioning unit assembly with the 7 bolts and nut.

      B008H7MN01

      Tech Tips

      Do not fully tighten the nut.

      Torque:
      Bolt A
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  3. INSTALL AIR DUCT ASSEMBLY


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

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

  4. CONNECT INSTRUMENT PANEL WIRE


    1. Connect the instrument panel wire with the bolts.

      B008IC2
      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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

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

    3. Connect the instrument panel junction block assembly with the and 3 nuts.

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

    4. Connect the connectors and attach the clamps.

    5. Connect the 3 ground wires with the 3 bolts.

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

  5. INSTALL REAR NO. 1 AIR DUCT


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

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


    1. B008J1HN01

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

      Tech Tips

      Do not fully tighten screw A.

    2. Install the ground wire with the bolt.

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

    3. Attach the 3 clamps to install the wire harness.

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


    1. B008IJXN01

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

      Tech Tips

      Do not fully tighten screw A.

    2. Attach the 4 clamps to install the wire harness.

  8. INSTALL NO. 1 AIR DUCT


    1. Attach the 3 claws to install a new No. 1 air duct.

      Note

      If the No. 1 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace with a new one.

  9. INSTALL NO. 2 AIR DUCT


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

      Note

      If the No. 2 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace with a new one.

    2. Attach the clamp.

  10. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Tighten the 3 bolts, 2 screws and nut as shown in the illustration.

      B008IUGN01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  11. CONNECT DRAIN COOLER HOSE


    1. B008HCIC01
      *a View A
      *b

      for LHD: Paint Mark (White)

      for RHD: Paint Mark (Yellow)
      *c Upward
      *d Engine Room Side

      Connect the drain cooler hose as shown in the illustration.

      Note


      • Install the drain cooler hose with its paint mark facing upward.

      • Make sure that the drain cooler hose is not twisted.

  12. INSTALL REAR NO. 2 AIR DUCT


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

    2. Install the clip.

  13. INSTALL REAR NO. 3 AIR DUCT


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

    2. Install the clip.

    3. Return the front floor carpet assembly to its original position with the 2 clips.

  14. INSTALL FRONT SEAT ASSEMBLY LH


    1. for Manual Seat:

      Click here

    2. for Power Seat:

      Click here

  15. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. Attach the 6 claws to install the lower defroster nozzle assembly.

  17. INSTALL STEERING COLUMN ASSEMBLY (for Manual Tilt and Manual Telescopic Steering Column)

    Click here

  18. INSTALL STEERING COLUMN ASSEMBLY (for Power Tilt and Power Telescopic Steering Column)

    Click here

  19. INSTALL LOWER INSTRUMENT PANEL

    Click here

  20. CONNECT WATER HOSE SUB-ASSEMBLY B


    1. B008JIWC01
      *A for 8AR-FTS
      *B for 3ZR-FAE
      *a View A
      *b

      Water Hose Sub-assembly B Paint Mark

      for 8AR-FTS: Green

      for 3ZR-FAE: Blue
      *c Clip installation angle (270°)

      Connect the water hose sub-assembly B with the paint mark facing left and attach the clip within the area shown in the illustration.

      Note

      Do not apply excessive force to the water hose sub-assembly B.

  21. CONNECT HEATER WATER OUTLET HOSE A


    1. B008GQSC01
      *A for 8AR-FTS
      *B for 3ZR-FAE
      *a View A
      *b

      heater water outlet hose A Paint Mark

      for 8AR-FTS: Green

      for 3ZR-FAE: Blue
      *c Clip installation angle (270°)

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

      Note

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

  22. CONNECT AIR CONDITIONING TUBE & ACCESSORY ASSEMBLY (for Sub-cool Accelerator)


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

    2. Sufficiently apply compressor oil to 2 new O-rings 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 conditioner tube and accessory assembly.

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. Connect the air conditioning tube and accessory assembly.

    5. B008GZB

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

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

  23. CONNECT LIQUID PIPE SUB-ASSEMBLY (except Sub-cool Accelerator)


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

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

      Compressor Oil
      for HFC-134a(R134a)
      ND-OIL 8 or equivalent
      for HFO-1234yf(R1234yf)
      ND-OIL 12 or equivalent

    3. Install the O-ring to the liquid pipe sub-assembly.

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. Connect the liquid pipe sub-assembly.

  24. CONNECT SUCTION PIPE SUB-ASSEMBLY (except Sub-cool Accelerator)


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

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

      Compressor Oil
      for HFC-134a(R134a)
      ND-OIL 8 or equivalent
      for HFO-1234yf(R1234yf)
      ND-OIL 12 or equivalent

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

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. Connect the suction pipe sub-assembly.

    5. B008GXD

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

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

  25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 8AR-FTS)

    Click here

  26. INSTALL NO. 2 CYLINDER HEAD COVER (for 3ZR-FAE)

    Click here

  27. ADD ENGINE COOLANT


    1. for 8AR-FTS:

      Click here

    2. for 3ZR-FAE:

      Click here

  28. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  29. WARM UP ENGINE


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  30. INSPECT FOR COOLANT LEAK


    1. for 8AR-FTS:

      Click here

    2. for 3ZR-FAE:

      Click here

  31. INSPECT FOR REFRIGERANT LEAK


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  32. INITIALIZATION SERVO MOTOR

    Click here