HEATING / AIR CONDITIONING  AIR CONDITIONING UNIT  INSTALLATION  


PROCEDURE

Hide 82210K 1.INSTALL AIR CONDITIONING HARNESS ASSEMBLY (for Automatic Air Conditioning System)

a.

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

E337540


b.

Connect each connector.


c.

Engage each clamp to install the air conditioning harness assembly.


Hide 88539J 2.INSTALL DRAIN COOLER HOSE

a.
E291807C01
2.583,0.667 2.875,0.521 false 2.031,0.448 2.563,0.698 false 2.896,0.396 3.208,0.594 0.313,0.198 10 false *a 1.854,0.313 2.167,0.51 0.313,0.198 10 false *b
*a Hose Notch
*b Rib


Align the hose notch with the rib as shown in the illustration and install the drain cooler hose.


Hide 88650N 3.INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (for Manual Air Conditioning System)

a.

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

E260961


b.

Install the air conditioning amplifier assembly with the screw.


Hide 88650N 4.INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (for Automatic Air Conditioning System)

a.

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

E260962


b.

Install the air conditioning amplifier assembly with the screw.


c.

Connect the connector.


Hide 55388C 5.INSTALL CONSOLE MOUNTING BRACKET RH

a.

Install the console mounting bracket RH with the screw.


Hide 55389A 6.INSTALL CONSOLE MOUNTING BRACKET LH

a.

Engage the 2 claws to install the console mounting bracket LH.


Hide 88505 7.INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY (for Automatic Air Conditioning System)

a.

Engage the 2 claws to install the air conditioning duct sub-assembly.


b.

Engage the clamp.


Hide 87050 8.INSTALL AIR CONDITIONING RADIATOR ASSEMBLY

a.

Install the air conditioning radiator assembly with the 3 screws.


b.

for Automatic Air Conditioning System:

i.

Connect the connector.



Hide 87211A 9.INSTALL NO. 2 AIR DUCT

a.

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

NOTICE:

If any of the claws of the No. 2 air duct are cracked or deformed, make sure to replace the No. 2 air duct with a new one. Failure to do so may cause the No. 2 air duct to fall off or noise to occur.



Hide 87211 10.INSTALL NO. 1 AIR DUCT

a.

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

NOTICE:

If any of the claws of the No. 1 air duct are cracked or deformed, make sure to replace the No. 1 air duct with a new one. Failure to do so may cause the No. 1 air duct to fall off or noise to occur.



Hide 11.TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

a.

Temporarily install the air conditioner unit assembly with the bolt and nut.

NOTICE:

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



b.

Connect the drain cooler hose.


Hide 55331 12.INSTALL INSTRUMENT PANEL REINFORCEMENT

a.

Install the instrument panel reinforcement with the 5 bolts (A).

E294882C01
1.25,1.688 1.302,1.688 false
V100135

Bolt (A)
V100136

Bolt (B)



b.

Temporarily install the 3 bolts (B).


Hide 55306A 13.INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

a.

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

HINT:

Do not fully tighten the screw.



b.
E282681

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


c.

Install the clip.


Hide 55306A 14.INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

a.

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

HINT:

Do not fully tighten the screw.



b.
E294883

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


c.

Install the clip.


Hide 82141 15.CONNECT INSTRUMENT PANEL WIRE

a.

Engage each clamp.

E291799C03
2.75,1.583 2.615,1.125 false 6.667,1.656 6.25,1.385 false 3.396,5.969 3.479,5.719 false 2.708,1.594 3.021,1.792 0.313,0.198 10 false *a 2.958,0.375 3.24,0.583 0.281,0.208 12 true *A 6.688,1.594 7,1.792 0.313,0.198 10 false *b 0.167,5.333 0.458,5.552 0.292,0.219 12 true *A 1.583,5.333 1.885,5.552 0.302,0.219 12 true *B 3.302,5.979 3.594,6.198 0.292,0.219 12 true *A
*A for Manual Air Conditioning System *B for Automatic Air Conditioning System
*a Ground Portion of Wire Harness Protector Cover *b Earth Wire
V100135

Bolt (A)
V100136

Bolt (B)
V100137

Connector - -



b.

Connect each connector.


c.

Connect the instrument panel wire with the 4 bolts (B).


d.

Connect the ground portion of the wire harness protector cover and earth wire with the 2 bolts (A).

Torque:
8.5 N*m (87 kgf*cm, 75 in.*lbf)


Hide 16.FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY

a.

Tighten the 4 bolts, 2 screws and nut.

E294884C01
2.229,1.552 2.385,1.75 0.156,0.198 10 true 2 4.021,0.969 4.177,1.167 0.156,0.198 10 true 3 6.042,0.677 6.198,0.875 0.156,0.198 10 true 1 1.625,5.802 1.781,6 0.156,0.198 10 true 7 2.49,6 2.646,6.198 0.156,0.198 10 true 6 4.375,5.802 4.531,6 0.156,0.198 10 true 5 5.583,5.49 5.74,5.688 0.156,0.198 10 true 4
V100135

Bolt
V100136

Screw
V100137

Nut - -


Torque:
Bolt, Nut : 9.8 N*m (100 kgf*cm, 87 in.*lbf)
Screw : 4.0 N*m (41 kgf*cm, 35 in.*lbf)

NOTICE:

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



Hide 55343B 17.INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE

a.

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


Hide 55950G 18.INSTALL DEFROSTER NOZZLE ASSEMBLY

a.

Engage the 6 claws to install the defroster nozzle assembly.


Hide 88625Q 19.INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)

a.

Connect the connector and air conditioning duct sub-assembly to install the cooler (room temp. sensor) thermistor.


Hide 20.INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

Click herePower Source / Network>POWER DISTRIBUTION>MAIN BODY ECU>INSTALLATION

Hide 85940 21.INSTALL WINDSHIELD WIPER RELAY ASSEMBLY (w/ Rain Sensor)

Click hereVehicle Exterior>WIPER / WASHER>WIPER ECU>INSTALLATION

Hide 89650 22.INSTALL POWER STEERING ECU ASSEMBLY

Click hereSteering>POWER ASSIST SYSTEMS>POWER STEERING ECU>INSTALLATION

Hide 23.INSTALL STEERING COLUMN ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION

Hide 55303B 24.INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY

Click hereVehicle Interior>INTERIOR PANELS / TRIM>LOWER INSTRUMENT PANEL>INSTALLATION

Hide 87245 25.CONNECT HEATER WATER INLET HOSE

a.
E291798C01
1.365,2.781 1.667,2.99 false 2.26,1.063 2.417,1.26 0.156,0.198 10 false A 0.417,2.5 0.729,2.698 0.313,0.198 10 false *a 1.188,2.656 1.5,2.854 0.313,0.198 10 false *b 1.656,4.375 1.969,4.573 0.313,0.198 10 false *c
*a View A
*b Marking (White)
*c Clip Installation Angle (270°)


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

NOTICE:

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



Hide 87246 26.CONNECT HEATER WATER OUTLET HOSE

a.
E291796C01
1.406,2.792 1.677,2.969 false 2.271,0.896 2.427,1.094 0.156,0.198 10 false A 0.5,2.417 0.813,2.615 0.313,0.198 10 false *a 1.656,2.333 1.969,2.531 0.313,0.198 10 false *c 1.24,2.656 1.552,2.854 0.313,0.198 10 false *b
*a View A
*b Marking (White)
*c Clip Installation Angle (270°)


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

NOTICE:

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



Hide 88710 27.CONNECT AIR CONDITIONER TUBE ASSEMBLY

a.

Remove the vinyl tape from the air conditioner tube assembly.


b.

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



c.

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

NOTICE:

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



d.

Connect the air conditioner tube assembly.


Hide 88707 28.CONNECT SUCTION PIPE SUB-ASSEMBLY

a.

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


b.

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



c.

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

NOTICE:

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



d.

Connect the suction pipe sub-assembly.


e.
E282674

Rotate the hook connector as shown in the illustration.


f.

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

Torque:
9.8 N*m (100 kgf*cm, 87 in.*lbf)


Hide 29.INSPECT FOR COOLANT LEAK (for 2NZ-FE)

Click hereEngine / Hybrid System>2NZ-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide 30.INSPECT FOR COOLANT LEAK (for 1ZR-FE)

Click hereEngine / Hybrid System>1ZR-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide 31.INSPECT FOR COOLANT LEAK (for 2ZR-FE)

Click hereEngine / Hybrid System>2ZR-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide 32.INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK (for 2NZ-FE)

Click hereEngine / Hybrid System>2NZ-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide 33.INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK (for 1ZR-FE)

Click hereEngine / Hybrid System>1ZR-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide 34.INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK (for 2ZR-FE)

Click hereEngine / Hybrid System>2ZR-FE COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Hide 35.CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT