RM36D0EC _58 Vehicle Interior _083104 HEATING / AIR CONDITIONING _0417475 AIR CONDITIONING UNIT(for M20C-FKS) A

HEATING / AIR CONDITIONING  AIR CONDITIONING UNIT(for M20C-FKS)  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 88539G 1.INSTALL COOLER UNIT DRAIN HOSE GROMMET

NOTICE:
Perform this procedure only when removal/installation of the cooler unit drain hose grommet is necessary.

After removing the cooler unit drain hose grommet, replace it with a new one to prevent water from entering.


a.
E405842C01
1.021,3.344 1.292,3.344 true 0.865,3.24 1.177,3.438 0.313,0.198 10 false *a
*a Lip Penetrate Area


Attach one side of the lip on a new cooler unit drain hose grommet (approximately 1/3 of the circumference) to the body hole (fit it to the hole).


b.
E405843C01
0,0 0,0 false
V100155

Rib Upper Surface


Press the entire upper surface of the rib on the cooler unit drain hose grommet, and fit the entire circumference of the lip to the hole.

NOTICE:
·

If the lip on the cooler unit drain hose grommet is not completely fit to the hole, water or noise may enter the interior. When fitting the lip to the hole, make sure that there are no gaps between the lip and body.

·

Do not allow any foreign matter to be trapped between the cooler unit drain hose grommet and installation area, as this may allow noise to enter.

·

Removing the cooler unit drain hose grommet after it has been installed damages the lip due to burrs on the body punch hole (vehicle exterior). This may reduce contact between the edge of the lip and body and cause water to enter the interior. Therefore, do not reuse the cooler unit drain hose grommet.

·

When installing the cooler unit drain hose grommet, do not leave the lip only partially fit to the hole (as in the previous step). This may reduce contact due to lip deformation and cause water to enter the interior. Once you have started to install the part, complete the installation without stopping.




Hide 87201 2.INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

HINT:

Perform this procedure only when removal/installation of the No. 1 air duct sub-assembly is necessary.


a.
E405778N01
2.615,0.073 2.719,0.25 0.104,0.177 10 true 1 0.458,1.833 0.563,2.01 0.104,0.177 10 true 2

Install the No. 1 air duct sub-assembly with the 2 nuts in the order shown in the illustration.

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

NOTICE:
·

Make sure there are no cracks in the No. 1 air duct sub-assembly.

·

Make sure no foreign matter, such as the dash panel insulator, is trapped between the cowl and seal packing.

·

Make sure that the seal packing is securely attached to the cowl on the body. Look from the engine compartment and check that it does not drop down into the fresh air vent. (If foreign matter, such as the dash panel insulator, is trapped or if the seal packing is not securely attached, water or air from gaps may enter the interior.)




Hide 3.INSTALL AIR CONDITIONING 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 set the air conditioning unit assembly nearby the position where it is to be installed.

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.




b.

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

E415521


Hide 4.CONNECT INSTRUMENT PANEL WIRE

a.

Attach the clamp.

E415520


b.

Connect the connector.


Hide 6.INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING 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.

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

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.



E408777C01
0,0 0,0 false
V113147

Install in this Direction - -



b.

Temporarily install the 4 bolts (C).

E408773C01
0,0 0,0 false
V100135

Bolt (B)
V100136

Bolt (C)
V100137

Nut - -



c.

Temporarily install the bolt (B).


d.
E405772C01
0,0 0,0 false
V100135

Bolt (A)


Temporarily install the 3 bolts (A).


e.

Temporarily install the nut.


f.

Tighten the 4 bolts (C).

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


g.

Tighten the 3 bolts (A).

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


h.

Tighten the bolt (B).

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


Hide 87128 7.INSTALL HEATER GROMMET

a.
E405846C01
1.51,4 1.51,3.792 true 1.51,3.333 1.51,3.188 true 1.438,4 1.75,4.198 0.313,0.198 10 false *a 1.427,3.313 1.74,3.51 0.313,0.198 10 false *a
*a Spool


Install the heater grommet.

NOTICE:
·

Push the heater 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 grommet does not sit on top of the spools of the heater pipes.

·

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

·

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




Hide 88539J 8.CONNECT DRAIN COOLER HOSE

NOTICE:

If the cooler unit drain hose grommet was removed from the body, replace it with a new one.


a.
E405771

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

NOTICE:

When installing the drain cooler hose, make sure it is not twisted or crushed. Otherwise, water may leak into the interior.



b.

Attach the clamp.


Hide 55307C 9.TEMPORARILY INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

a.
E415517C01
0,0 0,0 false
V100135

Bolt
V100136

Nut
V100137

Screw


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


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

a.
E415516C01
0,0 0,0 false
V100135

Bolt
V100136

Nut
V100137

Screw


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


Hide 11.TIGHTEN INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY

a.

Tighten the 3 bolts, 2 nuts (A), and 2 screws in the order shown in the illustration.

HINT:

5 and 6 can be done in either order.


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

E415524C01
1.698,1.688 1.792,1.854 0.094,0.167 10 true 1 6.302,1.583 6.396,1.75 0.094,0.167 10 true 2 3.698,1.688 3.792,1.854 0.094,0.167 10 true 3 0.417,1.198 0.51,1.365 0.094,0.167 10 true 4 4.625,1.01 4.719,1.177 0.094,0.167 10 true 4 1.896,2.823 1.99,2.99 0.094,0.167 10 true 5 3.448,2.844 3.542,3.01 0.094,0.167 10 true 6 5.302,4.406 5.396,4.573 0.094,0.167 10 true 7
V100135

Bolt
V100136

Nut (A)
V100137

Nut (B)
V100138

Screw



b.

Tighten the nut (B).

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


c.
E409435

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

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


d.
E415525

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

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


Hide 12.CONNECT INSTRUMENT PANEL WIRE

a.

Attach the clamp.

E408768C01
3.208,5.375 3.375,5.563 0.167,0.188 10 true *a 4,3.802 4.167,3.99 0.167,0.188 10 true *a 1.625,3.865 1.792,4.052 0.167,0.188 10 true *a 1.479,4.917 1.646,5.104 0.167,0.188 10 true *a 3.771,1.208 3.938,1.396 0.167,0.188 10 true *a 2.344,0.729 2.51,0.917 0.167,0.188 10 true *a 2.646,0.802 2.813,0.99 0.167,0.188 10 true *a 5.344,1.417 5.51,1.604 0.167,0.188 10 true *a 4.063,2.604 4.229,2.792 0.167,0.188 10 true *a 4.917,2.833 5.083,3.021 0.167,0.188 10 true *a 5.073,4.354 5.24,4.542 0.167,0.188 10 true *a 1.969,0.427 2.135,0.615 0.167,0.188 10 true *a 1.542,0.323 1.719,0.479 0.177,0.156 10 true *b 5.104,5 5.271,5.188 0.167,0.188 10 true *b
*a Clamp *b Guide
V100135

Bolt
V100136

Connector



b.

Connect the connector.


c.

Attach the guide.


d.

Connect the 2 ground wires with the 2 bolts.

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


Hide 15.CONNECT INSTRUMENT PANEL WIRE

a.

Connect the lever connector.

Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>CENTER AIRBAG SENSOR ASSEMBLY>INSTALLATION

E425221C02
0.76,1.292 0.927,1.479 0.167,0.188 10 true *a 3.104,1.458 3.271,1.646 0.167,0.188 10 true *a 3.365,2.531 3.531,2.719 0.167,0.188 10 true *a 3.542,1.979 3.708,2.167 0.167,0.188 10 true *b 3.969,3.125 4.135,3.313 0.167,0.188 10 true *a 4.01,4.083 4.177,4.271 0.167,0.188 10 true *a 0.313,2.406 0.563,2.615 0.25,0.208 12 true *A
*A for Automatic Air Conditioning System - -
*a Clamp *b Guide
V100135

Bolt
V100136

Nut
V100137

Connector
V100138

Lever Connector



b.

Attach the clamp.


c.

Connect the connector.


d.

Attach the guide.


e.

Connect the ground wire with the bolt.

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


f.

Install the nut.

Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)


g.

Attach the clamp.

E408762C01
2.229,3.552 2.563,3.552 true 2.26,4.823 2.438,5.01 0.177,0.188 10 true *a 2.302,1.615 2.479,1.802 0.177,0.188 10 true *a 2.365,3.115 2.542,3.302 0.177,0.188 10 true *a 3.344,2.667 3.521,2.854 0.177,0.188 10 true *a 4.688,1.219 4.865,1.406 0.177,0.188 10 true *a 1.813,4.552 1.99,4.74 0.177,0.188 10 true *b 2.063,3.448 2.24,3.635 0.177,0.188 10 true *b 4.885,4.385 5.063,4.573 0.177,0.188 10 true *b 2.896,2.438 3.073,2.625 0.177,0.188 10 true *a
*a Clamp *b Guide



h.

Attach the guide.


i.

Connect the 3 ground wires with the 3 bolts.

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


j.
E434948C01
1.698,1.563 1.865,1.75 0.167,0.188 10 true *a 2,1.229 2.167,1.417 0.167,0.188 10 true *b
*a Clamp
*b Guide


Connect the 2 connectors.


k.

Attach the guide and clamp.


Hide 55085 18.INSTALL NO. 2 HEATER TO REGISTER DUCT SUB-ASSEMBLY

a.
E405760

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


Hide 58861B 19.INSTALL NO. 1 CONSOLE BOX DUCT

a.
E415513

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


Hide 87212G 20.INSTALL REAR NO. 3 AIR DUCT

a.
E415512

Attach the claw to install the rear No. 3 air duct.


Hide 87212H 21.INSTALL REAR NO. 4 AIR DUCT

a.
E405757

Attach the claw.


b.

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


Hide 87212 22.INSTALL REAR NO. 1 AIR DUCT

HINT:

Use the same procedure described as for the rear No. 3 air duct.


Hide 87212F 23.INSTALL REAR NO. 2 AIR DUCT

HINT:

Use the same procedure described as for the rear No. 4 air duct.


Hide 55215D 24.INSTALL NO. 3 DASH PANEL INSULATOR PAD

a.
E405756

Attach the guide to install the No. 3 dash panel insulator pad.


Hide 58510C 25.INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY

a.

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

E415526C01
0,0 0,0 false
V113147

Return to Original Position - -



b.

Attach the guide.


c.

Install the clip.


d.

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

E415527C01
0,0 0,0 false
V113147

Return to Original Position
V100155

Fastener



e.

Attach the guide.


f.

Attach each fastener.


g.

Install the clip.


Hide 58569D 26.INSTALL FRONT FLOOR CAUTION PLATE COVER

a.
E405751

Attach the 2 clips to install the front floor caution plate cover.


b.

While pressing at the positions shown in the illustration, attach the guide and claw.

E403899C01
0,0 0,0 false
V113146

Press Position - -



Hide 62414A 29.INSTALL LOWER CENTER PILLAR GARNISH LH

Hide 62413A 32.INSTALL LOWER CENTER PILLAR GARNISH RH

HINT:

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


Hide 73210 33.INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH

HINT:

Use the same procedure described as for the front seat outer belt assembly LH.


Hide 67917C 34.INSTALL REAR DOOR SCUFF PLATE RH

HINT:

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


Hide 40.INSTALL FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 87245 41.CONNECT INLET HEATER WATER HOSE

a.

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

NOTICE:
·

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

·

Make sure 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.



E408779C01
4.76,2.604 5.094,2.604 true 4.115,3.115 4.448,3.115 true 5.583,3.354 5.583,3.521 5.583,3.521 5.917,3.521 true 1.677,1.771 1.792,1.938 0.115,0.167 10 true A 4.583,0.417 4.99,0.729 0.406,0.313 10 false *a 5.625,1.573 6.031,1.885 0.406,0.313 10 false *c 4.604,2.521 5.01,2.833 0.406,0.313 10 false *1 3.958,3.031 4.365,3.344 0.406,0.313 10 false *2 5.375,2.177 5.781,2.49 0.406,0.313 10 false *d 5.938,3.427 6.344,3.74 0.406,0.313 10 false *b
*1 Hose Clip *2 Inlet Heater Water Hose
*a View A *b Stopper
*c Hose Clip Installation Angle (270°) *d Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.))



b.

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


Hide 87246 42.CONNECT OUTLET HEATER WATER HOSE

a.

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

NOTICE:
·

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

·

Make sure 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.



E408780C01
4.75,2.604 5.083,2.604 true 4.094,3.115 4.427,3.115 true 5.594,3.365 5.594,3.531 5.594,3.531 5.927,3.531 true 1.667,1.417 1.781,1.583 0.115,0.167 10 true A 4.552,0.344 5.115,0.635 0.563,0.292 10 false *a 5.802,0.635 6.365,0.927 0.563,0.292 10 false *c 5.375,2.156 5.938,2.448 0.563,0.292 10 false *d 4.583,2.521 5.146,2.813 0.563,0.292 10 false *1 3.927,3.031 4.49,3.323 0.563,0.292 10 false *2 5.938,3.438 6.5,3.729 0.563,0.292 10 false *b
*1 Hose Clip *2 Outlet Heater Water Hose
*a View A *b Stopper
*c Hose Clip Installation Angle (270°) *d Hose Clip Installation Range (2 to 7 mm (0.0787 to 0.276 in.))



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 88710E 43.CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

a.

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


b.

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

Compressor Oil:

ND-OIL 8 or equivalent



c.

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

NOTICE:

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



d.
E405746

Connect the air conditioning tube and accessory assembly.

NOTICE:
·

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)




Hide 88707 44.CONNECT SUCTION PIPE SUB-ASSEMBLY

a.

Remove the vinyl tape wrapped around the connection of the suction pipe sub-assembly and 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 of foreign matter.



d.
E405745

Connect the suction pipe sub-assembly.

NOTICE:
·

Do not apply excessive force to the suction pipe sub-assembly.

·

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




e.
E405855C01
0,0 0,0 false
V113147

Rotate in this Direction


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


f.
E409430

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

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


Hide 45.INSTALL HOLE PLUG

a.
E409429

Install the 2 hole plugs.


Hide 55704B 46.INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY

a.

Install the cowl ventilator panel sub-assembly with the 4 bolts and 4 nuts.

Torque:
Bolt : 5.5 N*m (56 kgf*cm, 49 in.*lbf)
Nut : 21 N*m (214 kgf*cm, 15 ft.*lbf)

E409428C01
0,0 0,0 false
V100135

Bolt
V100136

Nut



b.

Attach the clamp.


Hide 50. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART