GSIC - Global Service Information Center

# AIR CONDITIONING UNIT > INSTALLATION

## for Preparation Click here

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY

1. Install the A/C unit with the bolt and nut.

   Torque:
     9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

2. INSTALL INSTRUMENT PANEL REINFORCEMENT

1. Install the instrument panel reinforcement with the 7 bolts.

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

1. Install the 3 bolts.

   Torque:
     9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

1. Connect the connectors.

1. Attach the 12 clamps.

1. Install the grommet to the vehicle body.

1. Connect the ground wires to the instrument panel reinforcement with the 2 bolts.

1. Connect the connector and wire harness.

1. w/o PTC heater:
   Attach the 2 clamps.

1. w/ PTC heater:
   Attach the 3 clamps.

1. Connect the connector and wire harness.

1. Attach the 2 clamps.

3. INSTALL NO.1 COOLER UNIT DRAIN HOSE

1. Install the drain hose.

4. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (w/ Air Conditioning)

1. Install the A/C amplifier with the screw.

1. Connect the connector.

1. Attach the clamp to install the amplifier.

5. INSTALL NO. 4 AIR DUCT

1. Attach the 2 claws to install the duct.

6. INSTALL NO. 2 AIR DUCT

1. Attach the 2 claws to install the duct.

7. INSTALL NO. 1 AIR DUCT

1. Attach the 2 claws to install the duct.

8. INSTALL ECM

For 1TR-FE (Click here)
For 2TR-FE (Click here)
For 1GR-FE (Click here)
For 1KD-FTV (Click here)
For 2KD-FTV (Click here)

9. INSTALL STEERING COLUMN ASSEMBLY

1. Install the steering column with the 3 bolts.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

10. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

1. Connect the connectors to install the instrument panel junction block.

1. Attach the 2 clamps to install the brace.

1. Install the brace with the 3 nuts and 2 bolts.

11. INSTALL NO. 3 HEATER TO REGISTER DUCT

1. Attach the 4 claws to install the duct.

12. INSTALL NO. 1 HEATER TO REGISTER DUCT

1. Attach the 3 claws to install the duct.

13. INSTALL NO. 2 HEATER TO REGISTER DUCT

1. Install the clip and duct.

14. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER

1. Install the instrument panel sub-assembly lower (Click here).

15. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY UPPER

1. Install the instrument panel sub-assembly upper (Click here).

16. CONNECT WATER HOSE SUB-ASSEMBLY

1. Connect the water hose and attach the clip.

17. CONNECT WATER HOSE SUB-ASSEMBLY B

HINT:

  Use the same procedures described for the water hose.

18. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/ Air Conditioning)

1. Remove the vinyl tape attached to the tube.

1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the A/C tube.

   Compressor oil:
     ND-OIL 8 or equivalent

1. Install the 2 O-rings on the A/C tube.

1. Connect the A/C tube & accessory and attach the piping clamp.

19. CONNECT SUCTION TUBE SUB-ASSEMBLY (w/ Air Conditioning)

1. Remove the vinyl tape attached to the tube.

1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the suction tube.

   Compressor oil:
     ND-OIL 8 or equivalent

1. Install the 2 O-rings on the suction tube.

1. Connect the suction tube and attach the piping clamp.

   HINT:
     After the connection, check that the claw of the piping clamp is engaged.

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

21. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

22. CHECK SRS WARNING LIGHT

1. Check the SRS warning light (Click here).

23. ADD ENGINE COOLANT

For 1TR-FE (Click here)
For 2TR-FE (Click here)
For 1GR-FE (Click here)
For 1KD-FTV (Click here)
For 2KD-FTV (Click here)

24. CHARGE REFRIGERANT

1. Perform vacuum purging using a vacuum pump.

1. Charge refrigerant HFC-134a (R134a).

   Standard:
     450 +- 30 g (15.87 +- 1.05 oz.)
   SST
     07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

   NOTICE:
   1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   1. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

25. WARM UP ENGINE

1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

   NOTICE:
     Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

26. CHECK FOR ENGINE COOLANT LEAKS

For 1TR-FE (Click here)
For 2TR-FE (Click here)
For 1GR-FE (Click here)
For 1KD-FTV (Click here)
For 2KD-FTV (Click here)

27. CHECK FOR LEAKAGE OF REFRIGERANT

1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

1. Perform the operation under these conditions:

   1. Stop the engine.
   1. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   1. Repeat the test 2 or 3 times.
   1. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

1. Using a gas leak detector, check the refrigerant line for leakage.

1. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

1. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.