RM35X0E _58 Vehicle Interior _079316 HEATING / AIR CONDITIONING _0384874 FRONT AIR CONDITIONING UNIT(for LHD) A

HEATING / AIR CONDITIONING  FRONT AIR CONDITIONING UNIT(for LHD)  INSTALLATION  


CAUTION / NOTICE / HINT

HINT:

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

Click hereGeneral>SPECIFICATIONS>STANDARD BOLT>SPECIFIED TORQUE FOR STANDARD BOLTS


PROCEDURE

Hide 88539D 1.INSTALL COOLER UNIT DRAIN PIPE

HINT:

Perform this procedure only when removal/installation of the cooler unit drain pipe is necessary.


a.
E417311

Install the piping clamp with 2 screws.


Hide 88539C 2.INSTALL NO. 2 COOLER UNIT DRAIN HOSE

HINT:

Perform this procedure only when removal/installation of the No. 2 cooler unit drain hose is necessary.


a.
E400914

Install the No. 2 cooler unit drain hose to cooler unit drain pipe.


b.
E400913

Temporarily install the cooler unit drain pipe with No. 2 cooler unit drain hose.


c.

Install the cooler unit drain pipe with No. 2 cooler unit drain hose with the bolt and attach the clamp.


Hide 88539 3.INSTALL NO. 1 COOLER UNIT DRAIN HOSE

NOTICE:
Perform this procedure only when removal/installation of the No. 1 cooler unit drain hose is necessary.

After removing the No. 1 cooler unit drain hose, replace it with a new one to prevent water from entering.


a.
E416478C01
3.094,0.219 2.896,0.375 true 3.104,0.115 3.323,0.313 0.219,0.198 10 true *a
*a Marking
V113147

Install in this Direction


Install the No. 1 cooler unit drain hose.

NOTICE:

Install the No. 1 cooler unit drain hose with its paint mark facing upward.



b.
E400911

Connect the No. 1 cooler unit drain hose to cooler unit drain pipe.


Hide 7.INSTALL AIR CONDITIONER UNIT ASSEMBLY

NOTICE:
·

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.

·

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.

·

Do not allow the air conditioning unit assembly to strike the airbag ECU assembly. Doing so may damage the heater case, causing water leaks.



a.

Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 4 bolts.

E400910

NOTICE:
When carrying the air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts.
·

Do not hold the air conditioning harness assembly. Otherwise, static electricity from the technician may damage the air conditioning harness assembly.

·

Do not hold the heater core or pipe of the heater radiator unit sub-assembly. Otherwise, the pipe may detach, the clamp may be damaged, or the crimped areas of the heater core and pipe of the heater radiator unit sub-assembly may be damaged, causing coolant to leak.

·

Do not hold the air conditioning radiator damper servo sub-assembly, blower damper servo sub-assembly or link. Otherwise, the servo motor may become misaligned, causing abnormal operation noise, temperature control defects, or air leaks due to sealing defects in the doors.

·

Do not hold the door. Doing so may cause air leaks due to closing defects resulting from excessive opening/closing. Also, keep the door free from oil and grease.




Hide 8.INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:
·

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.

·

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



a.

Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly.

NOTICE:
·

Do not allow the heater radiator unit sub-assembly heater pipe or cooler expansion valve to strike the body.

·

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




b.

for Automatic Transmission:

i.

Install the instrument panel reinforcement assembly with the 8 bolts.

E400909C02
0.969,0.135 1.281,0.333 0.313,0.198 10 true *a 0.385,3.833 0.635,4.031 0.25,0.198 12 true *A
*A for Manual Transmission - -
*a Engine Room Side - -
V100135

Bolt A
V100136

Bolt B


Torque:
Bolt A : 25 N*m (255 kgf*cm, 18 ft.*lbf)
Bolt B : 23.6 N*m (241 kgf*cm, 17 ft.*lbf)



c.

for Manual Transmission:

i.

Install the instrument panel reinforcement assembly with the 9 bolts.

Torque:
Bolt A : 25 N*m (255 kgf*cm, 18 ft.*lbf)
Bolt B : 23.6 N*m (241 kgf*cm, 17 ft.*lbf)



d.
E400943C01
1.135,2.865 1.667,2.99 true 0.948,2.844 1.406,2.344 true 0.844,2.885 0.667,3.146 true 1.698,2.917 1.896,3.115 0.198,0.198 10 true *a 1.417,2.229 1.729,2.427 0.313,0.198 10 false *b 0.594,3.146 0.906,3.344 0.313,0.198 10 false *c
*a Standard Position
*b Hose Notch
*c Rib


Align the standard position, install the drain cooler hose.


e.

Tighten the nut.


Hide 55306A 10.INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

a.
E400905C02
0,0 0,0 false
V100135

Bolt
V100136

Nut


Install the No. 1 instrument panel brace sub-assembly with the 3 bolts and 2 nuts.

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


Hide 55307C 11.INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

a.
E400906C02
0,0 0,0 false
V100135

Bolt
V100136

Nut
V100137

Screw


Install the No. 2 instrument panel brace sub-assembly with the 2 bolts.

Torque:
20 N*m (204 kgf*cm, 15 ft.*lbf)


b.

Install the nut and screw.

Torque:
18 N*m (184 kgf*cm, 13 ft.*lbf)


Hide 12.INSTALL AIR CONDITIONER UNIT ASSEMBLY

a.

Tighten the 4 bolts in the order shown in the illustration.

Torque:
Bolt(A) : 10 N*m (102 kgf*cm, 7 ft.*lbf)

E416416C01
4.198,0.552 4.396,0.76 true 3.448,2.25 3.604,2.448 0.156,0.198 10 true 1 5.104,1.573 5.26,1.771 0.156,0.198 10 true 2 1.635,2.594 1.792,2.792 0.156,0.198 10 true 3 4.323,0.188 4.479,0.385 0.156,0.198 10 true 4 4.344,0.792 4.542,0.979 0.198,0.188 10 true *a
*a Bolt(A) - -



Hide 87201A 13.INSTALL AIR DUCT SUB-ASSEMBLY

a.
E400904

Temporarily install the air duct sub-assembly.


b.

Tighten the 2 nuts.


Hide 55950G 14.INSTALL DEFROSTER NOZZLE ASSEMBLY

E400907

a.

Attach the claw to install the defroster nozzle assembly.


Hide 82141 15.INSTALL INSTRUMENT PANEL WIRE

a.

Connect each connector and attach each clamp and install the instrument panel wire.

E421734C01
4.667,0.365 4.479,0.25 true 5.99,7.469 6.198,7.667 0.208,0.198 12 true *A 0.448,6.094 0.656,6.292 0.208,0.198 10 true *1 6.031,5.479 6.24,5.677 0.208,0.198 10 true *1 6.354,5.167 6.563,5.365 0.208,0.198 10 true *1 6.198,7.844 6.406,8.042 0.208,0.198 12 true *A 5.948,8.5 6.156,8.698 0.208,0.198 12 true *A 3.708,1.938 3.917,2.135 0.208,0.198 10 true *1 5.854,5.854 6.01,6.042 0.156,0.188 10 true A 4.271,0.156 4.479,0.333 0.208,0.177 10 true *2
*A w/ PTC Heater - -
*1 Ground Wire *2 Protector Cover
V100135

Connector
V100136

Bolt
V100137

Nut
V113147

Install in this Direction



b.

Install each nut.

Torque:
NUT A : 12.5 N*m (127 kgf*cm, 9 ft.*lbf)


c.

Attach the claw and install the protector cover together with the instrument panel wire.


d.

Attach the claw and close protector cover.


e.

Install each bolt and each ground wire.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)


Hide 58193G 16.INSTALL NO. 3 FRONT FLOOR FOOTREST

a.
E400902

Attach the clip to install the No. 3 front floor footrest.


Hide 58510D 17.INSTALL FRONT FLOOR CARPET ASSEMBLY

a.

w/ Console Box:

i.

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

E400945C01
0,0 0,0 false
V113147

Install in this Direction
V100155

Fastener



ii.

Attach each fastener.


iii.

Install the 4 clips.



b.

w/o Console Box:

i.

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

E416504C01
0,0 0,0 false
V113147

Install in this Direction
V100155

Fastener



ii.

Attach each fastener.


iii.

Install the 4 clips.



Hide 73570B 22.INSTALL REAR SEAT OUTER BELT ASSEMBLY (FLOOR ANCHOR) (for 4 Door, w/ Seat Belt)

Hide 73210 33.INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH (FLOOR ANCHOR)

HINT:

Use the same procedure described for the LH side.


Hide 35.INSTALL TRANSMISSION INSTRUMENT PANEL SHIFT ASSEMBLY (for Automatic Transmission)

Hide 87212F 38.INSTALL REAR NO. 2 AIR DUCT (w/ Rear Foot Duct)

E421730C01
0,0 0,0 false
V113147

Install in this Direction


a.

Install the rear No. 2 air duct as shown in the illustration.


Hide 87212G 39.INSTALL REAR NO. 3 AIR DUCT (w/ Rear Foot Duct)

a.
E421731C01
0,0 0,0 false
V113147

Install in this Direction


Install the rear No. 3 air duct as shown in the illustration.


Hide 87211 40.INSTALL NO. 1 AIR DUCT

a.
E400900

Attach the claw to install a new No. 1 air duct.


b.

Install the 2 bolts.

NOTICE:
·

When removing, do not crack or deform the lower heater case of the air conditioning radiator assembly.

·

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.




Hide 88897M 45.INSTALL HEATER PIPE GROMMET (w/ Heater System)

E416450C01
2.063,0.979 2.427,0.667 2.427,0.667 2.073,0.313 true 1.052,3.177 1.385,2.948 1.385,2.948 1.698,3.177 true 1.063,4.26 1.396,4.469 1.396,4.469 1.688,4.26 true 1.198,0.969 0.781,0.667 0.781,0.667 1.208,0.302 true 2.458,0.594 2.677,0.781 0.219,0.188 10 true *a 1.344,4.49 1.552,4.667 0.208,0.177 10 false *b 1.302,2.781 1.531,2.938 0.229,0.156 10 true *b 0.604,0.594 0.823,0.781 0.219,0.188 10 true *a
*a Marked Part
*b Spool


a.

Press the marked parts to attach the claw and install the heater pipe grommet.

NOTICE:
·

Push the heater pipe grommet lip seal until it passes over the spools of the heater pipes as shown in the illustration.

·

Make sure that the lip portion of the heater pipe grommet does not sit on top of the spools of the heater pipes.

·

Make sure that there is no gap between the heater pipe grommet and dash panel.

·

Securely fit the heater pipe grommet onto the dash panel. Otherwise, water may enter from the engine room or cause increased noise, vibration or harshness.




Hide 87245A 46.CONNECT HEATER WATER HOSE INLET A (w/ Heater System, for 1GD-FTV)

a.
E400946C04
0.688,3.865 0.688,4.188 false 0.292,3.802 0.292,4.167 false 0.927,3.792 0.927,4.417 0.927,4.417 1.167,4.417 true 2.448,3.167 2.448,2.99 2.448,2.99 2.063,2.99 false 0.615,4.198 0.927,4.396 0.313,0.198 10 false *1 0.24,4.177 0.552,4.375 0.313,0.198 10 false *2 1.198,4.354 1.51,4.552 0.313,0.198 10 false *b 2.76,0.844 2.99,1.031 0.229,0.188 10 true *a 1.906,2.896 2.219,3.094 0.313,0.198 10 false *c 0.76,2.635 1.073,2.833 0.313,0.198 10 false *d 3.198,3.719 3.396,3.896 0.198,0.177 10 false *e 2.417,2.583 2.729,2.781 0.313,0.198 10 false *a
*1 Hose Clip
*2 Heater Water Hose Inlet A
*a View A
*b Stopper
*c Marking (White or Blue or Brown)
*d Hose Clip Installation Range (7.5 mm (0.295 in.))
*e Clip Installation Angle (60°)


Connect the heater water hose inlet A with the marking facing left and attach the clip within the area shown in the illustration.

NOTICE:
·

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

·

Make sure the heater water hose inlet A is securely inserted to the stopper. However, if the end of the heater water hose inlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.

·

Connect the heater water hose inlet A so that its marking faces the top of the vehicle.




b.

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

NOTICE:

Make sure that the hose clamps do not contact each other.



Hide 87246A 47.CONNECT HEATER WATER HOSE OUTLET A (w/ Heater System, for 1GD-FTV)

a.
E400947C02
0.708,3.948 0.708,4.344 false 0.292,3.885 0.292,4.281 false 0.938,3.865 0.938,4.427 0.938,4.427 1.156,4.427 false 2.646,3.24 2.646,2.969 2.646,2.969 3.052,2.969 false 0.656,4.365 0.969,4.521 0.313,0.156 10 false *1 0.24,4.302 0.552,4.458 0.313,0.156 10 false *2 2.292,0.854 2.49,1.042 0.198,0.188 10 true *a 1.177,4.375 1.49,4.531 0.313,0.156 10 false *b 3.083,2.896 3.396,3.052 0.313,0.156 10 false *c 0.771,2.698 1.083,2.854 0.313,0.156 10 false *d 1.667,3.427 1.979,3.583 0.313,0.156 10 false *e 2.479,2.656 2.792,2.854 0.313,0.198 10 false *a
*1 Hose Clip
*2 Heater Water Hose Outlet A
*a View A
*b Stopper
*c Marking (White or Brown)
*d Hose Clip Installation Range (7.5 mm (0.295 in.))
*e Clip Installation Angle (60°)


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

NOTICE:
·

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

·

Make sure the heater water hose outlet A is securely inserted to the stopper. However, if the end of the heater water hose outlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.

·

Connect the heater water hose outlet A hose so that its marking faces the top of the vehicle.




b.

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

NOTICE:

Make sure that the hose clamps do not contact each other.



Hide 87246A 48.CONNECT HEATER WATER HOSE OUTLET A (w/ Heater System, for 7GR-FKS)

a.
E415158C01
2.625,3.271 2.625,2.979 2.625,2.979 2.99,2.979 false 0.688,3.969 0.688,4.375 false 0.281,3.896 0.281,4.26 false 0.927,3.875 0.927,4.5 0.927,4.5 1.146,4.5 false 0.625,4.375 0.938,4.531 0.313,0.156 10 false *1 0.229,4.271 0.542,4.427 0.313,0.156 10 false *2 0.646,0.75 0.844,0.927 0.198,0.177 10 true *a 1.167,4.417 1.479,4.573 0.313,0.156 10 false *b 3.031,2.906 3.344,3.063 0.313,0.156 10 false *c 0.76,2.708 1.073,2.865 0.313,0.156 10 false *d 1.667,3.406 1.979,3.563 0.313,0.156 10 false *e 2.448,2.594 2.76,2.792 0.313,0.198 10 false *a
*1 Hose Clip
*2 Heater Water Hose Outlet A
*a View A
*b Stopper
*c Marking (White or Yellow or Pink)
*d Hose Clip Installation Range (7.5 mm (0.295 in.))
*e Clip Installation Angle (60°)


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

NOTICE:
·

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

·

Make sure the heater water hose outlet A is securely inserted to the stopper. However, if the end of the heater water hose outlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.

·

Connect the heater water hose outlet A so that its marking faces the top of the vehicle.




b.

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

NOTICE:

Make sure that the hose clamps do not contact each other.



Hide 87245A 49.CONNECT HEATER WATER HOSE INLET A (w/ Heater System, for 7GR-FKS)

a.
E415157C01
0.979,3.823 0.979,4.438 0.979,4.438 1.198,4.438 false 2.448,3.219 2.448,3.031 2.448,3.031 1.958,3.031 false 0.323,3.833 0.323,4.302 false 0.76,3.906 0.76,4.375 false 1.198,0.844 1.406,1.042 0.208,0.198 10 true *a 1.229,4.365 1.542,4.563 0.313,0.198 10 false *b 1.802,2.948 2.115,3.146 0.313,0.198 10 false *c 0.813,2.656 1.125,2.854 0.313,0.198 10 false *d 3.219,3.76 3.406,3.948 0.188,0.188 10 false *e 0.708,4.385 1.021,4.583 0.313,0.198 10 false *1 0.271,4.313 0.583,4.51 0.313,0.198 10 false *2 2.406,2.573 2.719,2.771 0.313,0.198 10 false *a
*1 Hose Clip
*2 Heater Water Hose inlet A
*a View A
*b Stopper
*c Marking (Yellow or Pink)
*d Hose Clip Installation Range (7.5 mm (0.295 in.))
*e Clip Installation Angle (60°)


Connect the heater water hose inlet A with the marking facing left and attach the clip within the area shown in the illustration.

NOTICE:
·

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

·

Make sure the heater water hose inlet A is securely inserted to the stopper. However, if the end of the heater water hose inlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.

·

Connect the heater water hose inlet A so that its marking faces the top of the vehicle.




b.

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

NOTICE:

Make sure that the hose clamps do not contact each other.



Hide 88710C 50.CONNECT AIR CONDITIONING TUBE ASSEMBLY (w/ Cooler System, Sub-cool Accelerator)

a.

Remove the vinyl tape wrapped around the connection of the air conditioning tube assembly and the air conditioning tube assembly.


b.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assembly.

Compressor oil:

ND-OIL 8 or equivalent



c.

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

NOTICE:

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



d.
E400896

Connect the air conditioning tube assembly.

NOTICE:
·

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

·

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




e.
E400948C01
0,0 0,0 false
V113147

Install in this Direction


Rotate the 1-point tightening plate as shown in the illustration.


f.

Insert the tube joint into the fitting hole securely and tighten the bolt.

Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)


Hide 88716A 51.CONNECT COOLER REFRIGERANT LIQUID PIPE A (w/ Cooler System, w/o Sub-cool Accelerator)

a.

Remove the vinyl tape wrapped around the connection of the cooler refrigerant liquid pipe A.


b.

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

Compressor oil:

ND-OIL 8 or equivalent



c.

Install the O-ring to the cooler refrigerant liquid pipe A.

NOTICE:

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



d.
E400894

Connect the cooler refrigerant liquid pipe A.

NOTICE:
·

Do not apply excessive force to the cooler refrigerant liquid pipe A.

·

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




Hide 88717A 52.CONNECT COOLER REFRIGERANT SUCTION PIPE A (w/ Cooler System, w/o Sub-cool Accelerator)

a.

Remove the vinyl tape wrapped around the connection of the cooler refrigerant suction pipe A.


b.

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



c.

Install the O-ring to the cooler refrigerant suction pipe A.

NOTICE:

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



d.
E400893

Connect the cooler refrigerant suction pipe A.

NOTICE:
·

Do not apply excessive force to the cooler refrigerant suction pipe A.

·

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




e.
E400949C01
0,0 0,0 false
V113147

Install in this Direction


Rotate the 1-point tightening plate as shown in the illustration.


f.

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

Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)


Hide 58. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL