RM38N0EC _58 Vehicle Interior _111841 HEATING / AIR CONDITIONING _0499792 FRONT AIR CONDITIONING UNIT A

HEATING / AIR CONDITIONING FRONT AIR CONDITIONING UNIT INSTALLATION

PROCEDURE

Hide Display 1.TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

Hide Display 2.INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

NOTICE:: ·

Be sure to support the air conditioner unit assembly when installing it. 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.

Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

1,2.667 1.25,2.906 0.25,0.24 12 true *A 2.438,2.667 2.688,2.906 0.25,0.24 12 true *B

*A	w/o Seat Heater System	*B	w/ Seat Heater System
	Install in this Direction	-	-

Engage each clamp.

Connect each connector.

Install the instrument panel reinforcement assembly with air conditioner unit assembly with the 4 bolts (A).

0.063,1.417 0.271,1.625 0.208,0.208 10 true *a 3.979,3.385 4.167,3.594 0.188,0.208 10 true *c 2.385,2.313 2.563,2.49 0.177,0.177 10 true *b 0.052,0.385 0.26,0.594 0.208,0.208 10 true *a 6.802,2.427 7.01,2.635 0.208,0.208 10 true *a 6.802,3.156 7.01,3.365 0.208,0.208 10 true *a

*a	Bolt (A)	*b	Bolt (B)
*c	Nut	-	-

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

Install the bolt (B).

Torque:: 15 N*m (153 kgf*cm, 11 ft.*lbf)

Temporarily install the nut.

HINT:: Do not fully tighten the nut.

Install the 3 bolts.

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

Hide Display 55306A 3.INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

Temporarily install the nut and screw.

HINT:: Do not fully tighten the nut and screw.

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

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

Hide Display 55307E 4.INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

Temporarily install the nut and screw.

HINT:: Do not fully tighten the nut and screw.

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

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

Hide Display 5.INSTALL AIR CONDITIONER UNIT ASSEMBLY

Tighten the 3 bolts, 2 nuts (A), nut (B) and 2 screws to install the air conditioner unit assembly.

0.667,0.833 0.854,1 0.188,0.167 10 true *a 4.427,3.49 4.615,3.656 0.188,0.167 10 true *b 5.042,0.635 5.229,0.802 0.188,0.167 10 true *a 1.719,0.802 1.875,1 0.156,0.198 10 true 1 5.74,2.219 5.896,2.417 0.156,0.198 10 true 2 3.979,0.552 4.135,0.75 0.156,0.198 10 true 3 0.896,0.833 1.052,1.031 0.156,0.198 10 true 4 5.24,0.635 5.396,0.833 0.156,0.198 10 true 5 1.365,3.385 1.521,3.583 0.156,0.198 10 true 6 2.573,3.25 2.729,3.448 0.156,0.198 10 true 7 4.469,3.302 4.625,3.5 0.156,0.198 10 true 8

Nut (A)

Nut (B)

Torque:: Bolt : 9.8 N*m (100 kgf*cm, 87 in.*lbf); Nut (A) : 18 N*m (184 kgf*cm, 13 ft.*lbf); Nut (B) : 9.8 N*m (100 kgf*cm, 87 in.*lbf)

NOTICE:: Tighten the bolts, nuts (A), nut (B) and screws in the order shown in the illustration.

Hide Display 82141 6.CONNECT INSTRUMENT PANEL WIRE

Engage the 5 clamps.

3.844,0.604 4.656,0.156 true 4.667,0.063 4.979,0.219 0.313,0.156 10 false *a

*a	Lock Lever	-	-
	Move in this Direction	-	-

Connect the 2 connectors.

Temporarily connect the connector and then move the lock lever in the direction indicated by the arrow to securely connect the connector.

Engage each clamp.

Connect the connector.

Engage the 6 guides.

0.25,3.906 0.479,4.604 true 0.875,2.604 0.708,3.156 0.708,3.156 1.396,2.052 true 2.823,0.688 1.979,0.333 true 3.969,5.5 3.615,4.531 true 6.583,5.5 6.844,4.708 true 0.073,3.813 0.302,3.979 0.229,0.167 10 false *a 0.604,3.156 0.833,3.323 0.229,0.167 10 true *a 1.802,0.229 2.031,0.396 0.229,0.167 10 false *a 3.896,5.5 4.125,5.667 0.229,0.167 10 false *a 6.469,5.521 6.698,5.688 0.229,0.167 10 true *a 0.052,4.385 0.281,4.552 0.229,0.167 10 true *c 3.927,4.208 4.156,4.375 0.229,0.167 10 true *b 6.229,4.708 6.458,4.875 0.229,0.167 10 true *b 1.042,2.094 1.271,2.26 0.229,0.167 10 true *b 1.417,2.458 1.646,2.625 0.229,0.167 10 true *b 3.156,0.333 3.385,0.5 0.229,0.167 10 true *b

*a	Earth Wire	*b	Bolt (A)
*c	Bolt (B)	-	-

Connect the 6 earth wires with the 6 bolts.

Torque:: Bolt (A) : 8.5 N*m (87 kgf*cm, 75 in.*lbf); Bolt (B) : 10 N*m (102 kgf*cm, 7 ft.*lbf)

Install the nut.

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

Hide Display 7.INSTALL POWER DISTRIBUTION BOX ASSEMBLY WITH MAIN BODY ECU

Click herePower Source / Network>POWER DISTRIBUTION>MAIN BODY ECU>INSTALLATION202111,999999,_57,_111828,_0500082,RM100000001Z1A4_01_0007,

Hide Display 82877 8.INSTALL ECU INTEGRATION BOX RH

Click herePower Source / Network>NETWORKING>NETWORK GATEWAY ECU>INSTALLATION202111,999999,_57,_111829,_0503731,RM100000001ZFR0_01_0032,

Hide Display 55308B 9.INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

Click herePower Source / Network>POWER DISTRIBUTION>MAIN BODY ECU>INSTALLATION202111,999999,_57,_111828,_0500082,RM100000001Z1A4_01_0034,

Hide Display 10.INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY

for P710:

Click hereDrivetrain>P710 (HYBRID TRANSMISSION / TRANSAXLE)>SHIFT LEVER>INSTALLATION202203,999999,_52,_111805,_0503481,RM1000000021ZNL,

for K120:

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>SHIFT LEVER>INSTALLATION202303,999999,_52,_111806,_0499742,RM100000002B6JT,

Hide Display 88539G 11.INSTALL COOLER UNIT DRAIN HOSE GROMMET

HINT:: Perform this procedure only when replacement of the cooler unit drain hose grommet is necessary.

0.521,1.021 0.75,0.615 false 0.365,0.948 0.677,1.104 0.313,0.156 10 false *a

Lip

Install a new cooler unit drain hose grommet.

NOTICE:: ·

If the drain cooler hose is disconnected from the cooler unit drain hose grommet, make sure to replace the cooler unit drain hose grommet with a new one. Failure to do so may lead to water ingress.

·

Make sure that the entire lip of the cooler unit drain hose grommet is securely engaged to the vehicle body.

Hide Display 88539J 12.INSTALL DRAIN COOLER HOSE

2.438,1.146 2.24,0.74 true 1.719,0.479 2.188,0.708 true 2.458,1.063 2.646,1.24 0.188,0.177 10 true *a 1.521,0.396 1.708,0.573 0.188,0.177 10 true *b

*a	Hose Notch
*b	Rib

Align the hose notch with the rib as shown in the illustration and install the drain cooler hose to the upper heater case.

Engage the clip.

Connect the drain cooler hose to the cooler unit drain hose grommet.

Hide Display 55215D 13.INSTALL NO. 3 DASH PANEL INSULATOR PAD

Install the No. 3 dash panel insulator pad.

Hide Display 55085 14.INSTALL NO. 2 HEATER TO REGISTER DUCT SUB-ASSEMBLY

Install the No. 2 heater to register duct sub-assembly with the clip.

Hide Display 58861B 15.INSTALL NO. 1 CONSOLE BOX DUCT

Install the No. 1 console box duct with the clip.

Hide Display 87212 16.INSTALL REAR NO. 1 AIR DUCT

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

Hide Display 87212G 17.INSTALL REAR NO. 3 AIR DUCT

Engage the 2 claws to install the rear No. 3 air duct.

Hide Display 87212F 18.INSTALL REAR NO. 2 AIR DUCT

Engage the 4 claws.

Install the rear No. 2 air duct with the clip.

Hide Display 87212H 19.INSTALL REAR NO. 4 AIR DUCT

Engage the 4 claws.

Install the rear No. 4 air duct with the clip.

Hide Display 58510C 20.CONNECT FRONT FLOOR FRONT CARPET ASSEMBLY

for LH side:

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

ii.

Engage the 2 guides.

iii.

Install the clip.

for RH side:

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

ii.

Engage the 2 guides.

iii.

Install the clip.

Hide Display 58569D 21.INSTALL FRONT FLOOR CAUTION PLATE COVER

Engage the 2 clips.

Engage the 8 guides and 7 claws to install the front floor caution plate cover.

Hide Display 88734 22.INSTALL AIR CONDITIONING PARTICULATE MATTER SENSOR

Engage the guide.

Install the air conditioning particulate matter sensor with the 2 screws.

Hide Display 88505 23.INSTALL AIR CONDITIONING DUCT SUB-ASSEMBLY

Install the air conditioning duct sub-assembly with the screw.

Connect the aspirator.

Connect the connector.

Hide Display 88625Q 24.INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR

Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.

Hide Display 78010F 25.INSTALL ACCELERATOR PEDAL ASSEMBLY

for M20C-FKS, M20D-FKS:

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>ACCELERATOR PEDAL>INSTALLATION202111,999999,_51,_111785,_0503272,RM100000001ZEA5_01_0019,

for A25D-FXS, A25F-FXS:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>ACCELERATOR PEDAL SENSOR>INSTALLATION202111,999999,_51,_111804,_0501646,RM100000001Z74J_01_0019,

Hide Display 78118 26.INSTALL ACCELERATOR PEDAL PAD

for M20C-FKS, M20D-FKS:

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>ACCELERATOR PEDAL>INSTALLATION202111,999999,_51,_111785,_0503272,RM100000001ZEA5_01_0020,

for A25D-FXS, A25F-FXS:

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>ACCELERATOR PEDAL SENSOR>INSTALLATION202111,999999,_51,_111804,_0501646,RM100000001Z74J_01_0020,

Hide Display 27.INSTALL FRONT SEAT ASSEMBLY

for SFTM Made Manual Seat:

Click hereVehicle Interior>SEAT>FRONT SEAT ASSEMBLY (for SFTM Made Manual Seat)>INSTALLATION202203,999999,_58,_111839,_0501171,RM1000000022JSR,

for GTMC Made Manual Seat:

Click hereVehicle Interior>SEAT>FRONT SEAT ASSEMBLY (for GTMC Made Manual Seat)>INSTALLATION202203,999999,_58,_111839,_0525810,RM10000000229GD,

for SFTM Made Power Seat:

Click hereVehicle Interior>SEAT>FRONT SEAT ASSEMBLY (for SFTM Made Power Seat)>INSTALLATION202203,999999,_58,_111839,_0500775,RM1000000022JTB,

for GTMC Made Power Seat:

Click hereVehicle Interior>SEAT>FRONT SEAT ASSEMBLY (for GTMC Made Power Seat)>INSTALLATION202203,999999,_58,_111839,_0525811,RM10000000229GK,

Hide Display 28.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click hereVehicle Interior>INTERIOR PANELS / TRIM>INSTRUMENT PANEL SAFETY PAD>INSTALLATION202303,999999,_58,_111843,_0501135,RM100000002BEWI,

Hide Display 45250 29.INSTALL STEERING COLUMN ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION202409,999999,_55,_111820,_0503155,RM100000002OMWL,

Hide Display 30.INSTALL HOLE PLUG

Install the 2 hole plugs.

Hide Display 87245 31.CONNECT INLET HEATER WATER HOSE

Connect the inlet heater water hose as shown in the illustration.

1.917,2.583 2.146,2.198 false 4.729,3.521 4.729,3.208 false 4.563,2.531 4.917,2.74 false 5.219,3.156 5.375,3.552 false 0.833,1.906 1.146,2.063 0.313,0.156 10 false *a 2.167,2.094 2.479,2.25 0.313,0.156 10 false *b 1.823,3.469 2.135,3.625 0.313,0.156 10 false *c 3.396,1.458 3.552,1.656 0.156,0.198 10 true A 4.667,3.542 4.979,3.698 0.313,0.156 10 false *1 4.406,2.427 4.719,2.583 0.313,0.156 10 false *2 5.063,2.219 5.375,2.375 0.313,0.156 10 false *d 5.333,3.563 5.646,3.719 0.313,0.156 10 false *e

*1	Inlet Heater Water Hose	*2	Hose Clip
*a	View A	*b	Marking (White)
*c	Hose Clip Installation Angle (270°)	*d	Hose Clip Installation Range 2.0 to 7.0 mm (0.0787 to 0.276 in.)
*e	Stopper	-	-

NOTICE:: ·

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

·

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

·

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

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

Hide Display 87246 32.CONNECT OUTLET HEATER WATER HOSE

Connect the outlet heater water hose as shown in the illustration.

1.917,2.573 2.146,2.323 false 4.677,3.552 4.677,3.229 false 4.917,2.74 4.594,2.469 false 5.365,3.563 5.219,3.156 false 0.896,1.896 1.208,2.052 0.313,0.156 10 false *a 2.167,2.219 2.479,2.375 0.313,0.156 10 false *b 1.844,2.083 2.156,2.24 0.313,0.156 10 false *c 3,1.01 3.167,1.188 0.167,0.177 10 true A 4.615,3.563 4.927,3.719 0.313,0.156 10 false *1 4.438,2.375 4.75,2.531 0.313,0.156 10 false *2 5.313,3.563 5.625,3.719 0.313,0.156 10 false *e 5.063,2.229 5.375,2.385 0.313,0.156 10 false *d

*1	Outlet Heater Water Hose	*2	Hose Clip
*a	View A	*b	Marking (White)
*c	Hose Clip Installation Angle (270°)	*d	Hose Clip Installation Range 2.0 to 7.0 mm (0.0787 to 0.276 in.)
*e	Stopper	-	-

NOTICE:: ·

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

·

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

·

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