FRONT 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.

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

    Click here

PROCEDURE


  1. PRECAUTION

    Note


    • When installing the instrument panel reinforcement with air conditioner assembly, make sure to replace the No. 1 instrument panel spacer with a new one.

    • The part number for the No. 1 instrument panel spacer varies according to the installation position, either on the vehicle side or on the instrument panel reinforcement assembly side. Therefore, make sure to check before installing it.

    • B006D2X

      If it is necessary to replace the instrument panel extension spacer, use a new one of the same color as that which was removed.

  2. INSTALL NO. 1 INSTRUMENT PANEL SPACER


    1. Attach the claw to install the 2 new No. 1 instrument panel spacers to the instrument panel reinforcement assembly.

      B006F6T
    2. B006FL2

      Attach the claw to install a new No. 1 instrument panel spacers to the vehicle body.

  3. INSTALL AIR CONDITIONER UNIT ASSEMBLY

    Note


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

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


    1. Temporarily set the air conditioner unit assembly nearby the position where it is to be installed.

    2. Insert the instrument panel reinforcement assembly into the application area of the air conditioner unit assembly as shown in the illustration.

      B006C7IC01
      *A for LHD *B for RHD
      B006DHE Install in this Direction - -

    3. Install the 3 bolts in the order shown in the illustration.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    4. B006D6Q

      Attach the clamp.

    5. Connect the connector.

  4. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY


    1. B006CJD

      Attach the claw to install the lower defroster nozzle assembly.

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

    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 assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.


    1. Install the instrument panel reinforcement assembly with air conditioning unit assembly to the guide as shown in the illustration.

      Note


      • Be careful not to damage the internal components of the instrument panel reinforcement assembly and air conditioning unit assembly on the glass etc. Only perform installation after first taking the appropriate actions.

      • Make sure that both parts are securely installed to the guide.

      • Be sure to hold the air conditioning unit assembly by the case when carrying it.(Do not carry the air conditioning unit by holding the heater pipe, cooler pipe, servo motor, brushless motor, harness, air inlet door or link.)

      • Do not subject the air conditioning harness assembly connector to any strong impacts.

      B0069J5C01
      B006DHE After inserting it to the end, install the guide - -
    2. B006GPH

      Install the cooler pipe grommet.

      Note

      Make sure that the dash panel is securely inserted into the groove of the cooler pipe grommet without any gaps.

    3. B006E56

      Install the heater pipe grommet.

      Note

      Make sure that the dash panel is securely inserted into the groove of the heater pipe grommet without any gaps.

    4. Temporarily install the 4 bolts (D).

      B006CW9C01
      B006AHR Bolt (B) B006EC9 Bolt (C)
      B006FCW Bolt (D) B006FCW Nut

    5. Temporarily install the bolt (C).

    6. Using a universal socket wrench 12 mm, temporarily install the bolt (B).

    7. Using a universal socket wrench 12 mm, temporarily install the 2 bolts (A).

      B006CQHC01
      B006AHR Bolt (A) - -

    8. Temporarily install the nut.

    9. Tighten the 4 bolts (D).

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    10. Using a universal socket wrench 12 mm, tighten the bolt (B) and 2 bolts (A).

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    11. Tighten the bolt (C).

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    12. Tighten the nut.

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

  6. INSTALL DRAIN COOLER HOSE (for Front Passenger Side)


    1. B006GQ9

      Install the drain cooler hose (for front passenger side).

    2. Attach the guide.

  7. INSTALL DRAIN COOLER HOSE (for Driver's Side)


    1. B006FBN

      Install the drain cooler hose (for driver's side).

    2. Attach the guide.

  8. INSTALL NO. 3 HEATER TO REGISTER DUCT


    1. B006DCBC01
      B006AHR Screw
      B006EC9 Clip

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

    2. Install the screw.

  9. INSTALL NO. 2 HEATER TO REGISTER DUCT


    1. B0069VW

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

  10. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. B006B26C01
      B006DHE Lock in this Direction

      w/ VGRS:


      1. Connect the connector and move the lock as shown in the illustration.

        Note

        Be sure to connect the lever connector securely.

      2. Attach the clamp.

    2. Attach the clamp.

      B006EWR

    3. Connect the 3 connectors.

    4. Install the 2 nuts.

      Note

      If the removed nut is the same shape as that shown in the illustration, replace it the supplied replacement part.

      B006G7H
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  11. INSTALL INSTRUMENT PANEL WIRE (for RHD)


    1. B006CUQC01
      B006DHE Lock in this Direction

      w/ VGRS:


      1. Connect the connector and move the lock as shown in the illustration.

        Note

        Be sure to connect the lever connector securely.

      2. Attach the clamp.

    2. Attach the clamp.

      B006E3A

    3. Connect the connector.

    4. Install the 2 nuts.

      Note

      If the removed nut is the same shape as that shown in the illustration, replace it the supplied replacement part.

      B006G7H
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  12. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

    Click here

  13. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

    Click here

  14. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY


    1. B0069XKC01
      B006AHR Bolt
      B006EC9 Nut

      Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

      Torque:
      Bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Attach the clamp.

  15. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. Attach the clamp.

      B006AAT

    2. Connect the 2 connectors.

      Tech Tips

      The 2 connectors can be connected in any position (top or bottom).

  16. INSTALL INSTRUMENT PANEL WIRE (for RHD)


    1. Attach the clamp.

      B0069LO

    2. Connect the 2 connectors.

      Tech Tips

      The 2 connectors can be connected in any position (top or bottom).

  17. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for LHD)


    1. B006CB0C01
      B006AHR Bolt
      B006EC9 Nut
      B006FCW Screw

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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Install the screw.

    3. Attach the clamp.

  18. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for LHD)


    1. B006BAOC01
      B006AHR Bolt
      B006EC9 Nut
      B006FCW Screw

      Install the No. 2 instrument panel brace sub-assembly with the bolt and 2 nuts.

      Note

      If the removed nut is the same shape as that shown in the illustration, replace it the supplied replacement part.

      B006G7H
      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the screw.

    3. Attach the clamp.

  19. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for RHD)


    1. B006AD6C01
      B006AHR Bolt
      B006EC9 Nut
      B006FCW Screw

      Install the No. 2 instrument panel brace sub-assembly with the bolt and 2 nuts.

      Note

      If the removed nut is the same shape as that shown in the illustration, replace it the supplied replacement part.

      B006G7H
      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the screw.

  20. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for RHD)


    1. B006F9JC01
      B006AHR Bolt
      B006EC9 Nut
      B006FCW Screw

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

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Install the screw.

    3. Attach the clamp.

  21. INSTALL WIRING HARNESS CLAMP BRACKET


    1. B0069XI

      Install the wiring harness clamp bracket with the screw.

  22. INSTALL PASSENGER SIDE JUNCTION BLOCK ASSEMBLY WITH NETWORK GATEWAY ECU

    Click here

  23. INSTALL FRONT STEERING CONTROL ECU (w/ VGRS)

    Click here

  24. INSTALL ENGINE STOP AND START ECU (for LHD)

    Click here

  25. INSTALL ENGINE STOP AND START ECU (for RHD)

    Click here

  26. INSTALL SHIFT CONTROL ECU

    Click here

  27. INSTALL NO. 2 SEMICONDUCTOR POWER INTEGRATION ECU (w/ PTC Heater)

    Click here

  28. INSTALL SEMICONDUCTOR POWER INTEGRATION ECU (w/o PTC Heater)

    Tech Tips

    Use the same procedure as for the No. 2 semiconductor power integration ECU.

  29. INSTALL INSTRUMENT PANEL WIRE (for LHD)


    1. Attach the clamp.

      B006GGL

    2. Connect the connector.

    3. B006CEX

      Connect the connector.

    4. Attach the clamp.

  30. INSTALL INSTRUMENT PANEL WIRE (for RHD)


    1. Attach the clamp.

      B006BZ4

    2. Connect the 3 connectors.

    3. B006A0S

      Connect the connector.

    4. Attach the clamp.

  31. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY


    1. B006ENPC01
      B006DHE Install in this Direction

      Install the No. 2 air duct sub-assembly with the clip.

  32. INSTALL FRONT FLOOR MAT LH (for LHD)


    1. B0069HK

      Install the front floor mat LH.

  33. INSTALL FRONT FLOOR MAT LH (for RHD)


    1. Install the front floor mat LH.

      B006ETFC01
      *A for Rear Power Seat with Ottoman *B except Rear Power Seat with Ottoman

  34. INSTALL REAR NO. 2 AIR DUCT (for LHD)


    1. B006G8SC01
      B006DHE Install in this Direction

      Install the rear No. 2 air duct.

  35. INSTALL REAR NO. 2 AIR DUCT (for RHD)


    1. B006B2HC01
      *A for Rear Power Seat with Ottoman
      *B except Rear Power Seat with Ottoman
      B006DHE Install in this Direction

      Install the rear No. 2 air duct.

  36. INSTALL REAR AIR DUCT GUIDE LH


    1. B006BN3C01
      B006DHE Install in this Direction

      Attach the claw and install the rear air duct guide LH.

  37. INSTALL FRONT FLOOR MAT RH (for LHD)


    1. Install the front floor mat RH.

      B006EZJC01
      *A except Rear Power Seat with Ottoman *B for Rear Power Seat with Ottoman

  38. INSTALL FRONT FLOOR MAT RH (for RHD)


    1. B006AJ0

      Install the front floor mat RH.

  39. INSTALL REAR NO. 1 AIR DUCT (for LHD)


    1. B006G22C01
      *A except Rear Power Seat with Ottoman
      *B for Rear Power Seat with Ottoman
      B006DHE Install in this Direction

      Install the rear No. 1 air duct.

  40. INSTALL REAR NO. 1 AIR DUCT (for RHD)


    1. B006BOIC01
      B006DHE Install in this Direction

      Install the rear No. 1 air duct.

  41. INSTALL REAR AIR DUCT GUIDE RH

    Tech Tips

    Use the same procedure as for the rear air duct guide LH.

  42. INSTALL FRONT FLOOR CARPET ASSEMBLY FRONT (for LHD)


    1. Install the front floor carpet assembly front in the order shown in the illustration.

      B006DQHC01
      B006DHE Install in this Direction B006B42 Insert to the end

    2. Install the clip.

    3. Install the front floor carpet assembly front in the order shown in the illustration.

      B006F3DC01
      B006DHE Install in this Direction B006B42 Insert to the end

    4. Install the clip.

    5. B006D8M

      Attach the clamp.

      Tech Tips

      Use the same procedure for the opposite side.

  43. INSTALL FRONT FLOOR CARPET ASSEMBLY FRONT (for RHD)


    1. Install the front floor carpet assembly front in the order shown in the illustration.

      B006G7PC02
      B006DHE Install in this Direction B006B42 Insert to the end

    2. Install the clip.

    3. Install the front floor carpet assembly front in the order shown in the illustration.

      B006CM6C01
      B006DHE Install in this Direction B006B42 Insert to the end
      B006GBM Fastener - -

    4. Attach each fastener and guide.

    5. Install the clip.

    6. B0069ND

      Attach the clamp.

      Tech Tips

      Use the same procedure for the opposite side.

  44. INSTALL REAR NO. 3 AIR DUCT


    1. B006BL4C01
      B006DHE Install in this Direction

      Install the rear No. 3 air duct in the direction of the arrow shown in the illustration.

      Tech Tips

      Use the same procedure for both rear No. 3 air ducts.

    2. B006CPU

      Install the 2 screws.

      Tech Tips

      Use the same procedure for the opposite side.

  45. INSTALL AIR DUCT PLUG


    1. B006GHM

      Attach the claw to install the 2 air duct plugs.

      Tech Tips

      Use the same procedure for the opposite side.

  46. INSTALL FRONT FLOOR CAUTION PLATE COVER


    1. B006F8G

      Attach the claw and guide to install the front floor caution plate cover.

  47. INSTALL ACCELERATOR PEDAL

    Click here

  48. INSTALL ACCELERATOR PEDAL PAD

    Click here

  49. INSTALL LOWER CENTER PILLAR GARNISH LH

    Click here

  50. INSTALL REAR DOOR SCUFF PLATE LH

    Click here

  51. INSTALL LOWER CENTER PILLAR GARNISH RH

    Tech Tips

    Use the same procedure described for the lower center pillar garnish LH.

  52. INSTALL REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the rear door scuff plate LH.

  53. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape wrapped around the connection of the air conditioning tube and accessory assembly and 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
      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

    3. Install the 2 O-rings to the air conditioning tube and accessory assembly.

      Note

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

    4. Press in the air conditioning tube and accessory assembly until the shaft center of the pipe joint securely engages the seal hole.

      Note


      • Do not apply excessive force to the air conditioning tube and accessory assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

    5. w/o Rear Cooler:


      1. Rotate the 1-point tightening plate and align the 1-point tightening plate of air conditioning tube and accessory assembly with the tube marking (black).

        Note

        Make sure that the air conditioning tube and accessory assembly 1-point tightening plate is partially on the marking

        B006CE5C01
        *a View A *b Air Conditioning Tube and Accessory Assembly 1-Point Tightening Plate Marking
        *c Counterclockwise (OK) *d Standard
        *e Clockwise (OK) - -
        B006DHE Rotate in this Direction B006GBM Air Conditioning Tube and Accessory Assembly Marking

    6. w/ Rear Cooler:


      1. Rotate the 1-point tightening plate and align the 1-point tightening plate of air conditioning tube and accessory assembly with the tube marking (black).

        Note

        Make sure that the air conditioning tube and accessory assembly 1-point tightening plate is partially on the marking

        B006AUGC01
        *a View A *b Air Conditioning Tube and Accessory Assembly 1-Point Tightening Plate Marking
        *c Counterclockwise (OK) *d Standard
        *e Clockwise (OK) - -
        B006DHE Rotate in this Direction B006GBM Air Conditioning Tube and Accessory Assembly Marking
    7. B006EBZC02
      *A w/o Rear Cooler
      *B w/ Rear Cooler

      Install the bolt.

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

  54. INSTALL INLET HEATER WATER HOSE


    1. Install the inlet heater water hose as shown in the illustration.

      Note


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

      • Insert the inlet heater water hose until it contacts the stopper.

      B006AI4C01
      *1 Hose Clip *2 Inlet Heater Water Hose
      *a View A *b Marking (Green)
      *c Hose Clip Installation Angle (-15 to 15°) *d Stopper
      *e Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.)) - -

    2. Make sure to install the hose clip within the range shown in the illustration.

  55. INSTALL OUTLET HEATER WATER HOSE


    1. Install the outlet heater water hose as shown in the illustration.

      Note


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

      • Insert the outlet heater water hose until it contacts the stopper.

      B006A6PC01
      *1 Hose Clip *2 Outlet Heater Water Hose
      *a View A *b Marking (Green)
      *c Hose Clip Installation Angle (30 to 60°) *d Stopper
      *e Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.)) - -

    2. Make sure to install the hose clip within the range shown in the illustration.

  56. CONNECT INLET HEATER WATER HOSE

    Click here

  57. CONNECT OUTLET HEATER WATER HOSE

    Click here

  58. CONNECT NO. 14 CONNECTOR HOLDER


    1. for LHD:


      1. Attach the guide, claw and connect the No. 14 connector holder to the No. 17 connector holder.

        B006CD9C01
        B006DHE Connect in this Direction - -
      2. B006D70C01
        B006AHR Connector
        B006EC9 Lever Connector
        B006DHE Rotate in this Direction

        Attach the claw to connect the lever connector.

        Note

        Be sure to connect the lever connector securely.

      3. Connect the 2 connectors.

      4. B006E21

        Attach the claw to install the No. 1 semiconductor power integration ECU.

        Note


        • Make sure the connector terminal is free from oil and grease.

        • Do not subject the No. 1 semiconductor power integration ECU to any impact.

        • Do not use a No. 1 semiconductor power integration ECU that has been dropped.

        • Do not disassemble the No. 1 semiconductor power integration ECU.

      5. B006C2Z

        Connect the connector.

        Click here

      6. Attach the clamp.

    2. for RHD:


      1. Attach the guide, claw and connect the No. 14 connector holder to the No. 17 connector holder.

        B006FIHC01
        B006DHE Connect in this Direction - -
      2. B006ALLC01
        B006AHR Connector
        B006EC9 Lever Connector
        B006DHE Rotate in this Direction

        Attach the claw to connect the lever connector.

        Note

        Be sure to connect the lever connector securely.

      3. Connect the 2 connectors.

      4. B006E21

        Attach the claw to install the No. 1 semiconductor power integration ECU.

        Note


        • Make sure the connector terminal is free from oil and grease.

        • Do not subject the No. 1 semiconductor power integration ECU to any impact.

        • Do not use a No. 1 semiconductor power integration ECU that has been dropped.

        • Do not disassemble the No. 1 semiconductor power integration ECU.

      5. B006G6X

        Connect the connector.

        Click here

      6. Attach the clamp.

  59. INSTALL NO. 1 RELAY BLOCK COVER (for LHD)

    Click here

  60. INSTALL NO. 1 RELAY BLOCK COVER (for RHD)

    Click here

  61. INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH

    Click here

  62. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH

    Click here

  63. INSTALL HOLE PLUG


    1. B006H06

      Install the 2 hole plugs.

  64. INSTALL COWL VENTILATOR SPLASH SHIELD RH (for LHD)


    1. B006CWV

      Attach the claw.

    2. Attach the guide and clip to install the cowl ventilator splash shield RH.

  65. INSTALL COWL VENTILATOR SPLASH SHIELD LH (for RHD)

    Tech Tips

    Use the same procedure as for the cowl ventilator splash shield RH.

  66. INSTALL FRONT WIPER MOTOR AND LINK

    Click here

  67. INSTALL HEADUP DISPLAY (w/ Headup Display)

    Click here

  68. INSTALL STEERING COLUMN ASSEMBLY

    Click here

  69. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

    Click here

  70. INSTALL FRONT SEAT ASSEMBLY LH

    Click here

  71. INSTALL FRONT SEAT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the front seat assembly LH.

  72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

  73. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

    Click here

  74. ADD ENGINE COOLANT

    Click here

  75. INSPECT FOR COOLANT LEAK

    Click here

  76. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  77. WARM UP ENGINE


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  78. INSPECT FOR REFRIGERANT LEAK


    1. for HFC-134a(R134a):

      Click here

    2. for HFO-1234yf(R1234yf):

      Click here

  79. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

    Click here

  80. INSTALL TRANSMISSION UNDER COVER

    Click here

  81. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  82. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  83. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  84. INSTALL RADIATOR COVER PLATE

    Click here

  85. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  86. CHECK AND CLEAR DTC

    Click here