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AIR CONDITIONING > FRONT COOLING UNIT > INSTALLATION

1. INSTALL BLOWER UNIT ASSEMBLY

a. w/o PTC Heater:

Install the blower unit with the 2 screws.

b. w/ PTC Heater:
Install the blower unit with the 3 screws.

c. w/ PTC Heater:
Connect the clamp.

d. Connect the connector.

2. INSTALL NO. 2 AIR DUCT

a. Attach the claw to install the duct.

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3. INSTALL NO. 1 AIR DUCT

a. Attach the 2 claws to install the duct.

4. INSTALL DEFROSTER NOZZLE ASSEMBLY

a. Attach the 4 claws to install the nozzle.

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5. INSTALL HEATER TO REGISTER DUCT CENTER

a. Install the duct with the screw.

6. INSTALL AIR CONDITIONING UNIT ASSEMBLY

a. Install the air conditioning unit with the nut.

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

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7. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

a. Install the instrument panel reinforcement with the 11 bolts.

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

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b. Install the brace with the 3 bolts, 2

screws and 2 nuts.

c. Attach the clamps and connectors to the

wire harness.

d. Install the ground wire and junction block with the 7 bolts and 4 nuts.

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8. INSTALL NO. 2 INSTRUMENT PANEL TO COWL BRACE

a. Install the brace with the bolt and nut.

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9. INSTALL LOWER INSTRUMENT PANEL

a. Install the lower instrument panel (Refer to INSTRUMENT PANEL > LOWER INSTRUMENT
PANEL > INSTALLATION(200611 - )).

10. INSTALL UPPER INSTRUMENT PANEL

a. Install the upper instrument panel (Refer to INSTRUMENT PANEL > UPPER INSTRUMENT
PANEL > INSTALLATION(200611 - )).

11. INSTALL STEERING COLUMN ASSEMBLY

a. Install the steering column (Refer to STEERING COLUMN > STEERING COLUMN ASSEMBLY >
INSTALLATION(200611 - )).

12. CONNECT HEATER WATER OUTLET HOSE

a. Connect the water hose and attach the

clip.

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13. CONNECT HEATER WATER INLET HOSE

HINT:
Use the same procedures described for the water outlet hose.

14. CONNECT TUBE SUB-ASSEMBLY

a. Remove the attached vinyl tape from the

pipe.

b. Sufficiently apply compressor oil to new 2

O-rings and the fitting surface of the
suction tube and liquid tube.

Compressor oil:
ND-OIL 8 or equivalent

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

and liquid tube.

d. Connect the suction tube and liquid tube.

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

e. Install the plate with the bolt.

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

15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

16. CHECK SRS WARNING LIGHT

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a. Check the SRS warning light (Refer to SUPPLEMENTAL RESTRAINT SYSTEM > AIRBAG
SYSTEM > DIAGNOSIS SYSTEM(200601 - )).

17. ADD ENGINE COOLANT

for 2AZ-FE: (Refer to 2AZ-FE COOLING > COOLANT > REPLACEMENT(200601 - ))
for 2GR-FE: (Refer to 2GR-FE COOLING > COOLANT > REPLACEMENT(200706 - ))

18. CHARGE REFRIGERANT

a. Perform vacuum purging using a vacuum pump.

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

Standard:
750 +/-30 g (26.5 +/-1.1 oz.)

SST
07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-
78050, 07117-88060, 07117-88070, 07117-88080)

NOTICE:
 Do not operate the cooler compressor before charging refrigerant as the cooler
compressor will not work properly without any refrigerant, and will overheat.
 Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles
disappear. The refrigerant amount should be checked by measuring its quantity, and
not with the sight glass.

19. WARM UP ENGINE

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

20. CHECK FOR ENGINE COOLANT LEAKS

for 2AZ-FE: (Refer to 2AZ-FE COOLING > COOLING SYSTEM > ON-VEHICLE INSPECTION(200601
- ))
for 2GR-FE: (Refer to 2GR-FE COOLING > COOLING SYSTEM > ON-VEHICLE INSPECTION(200611
- ))

21. CHECK FOR LEAKAGE OF REFRIGERANT

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

b. Perform the operation under these conditions:

 Stop the engine.
 Secure good ventilation (the gas leak detector may react to volatile gases other than
refrigerant, such as evaporated gasoline or exhaust gas).
 Repeat the test 2 or 3 times.
 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)

c. Using a gas leak detector, check the

refrigerant line for leakage.

d. 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.

e. 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.

22. PERFORM INITIALIZATION

a. Perform initialization (Refer to INTRODUCTION > REPAIR INSTRUCTION > INITIALIZATION

(200611 - )).

NOTICE:

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

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