Air Conditioning Unit

Air Conditioning Unit:

AIR CONDITIONING UNIT

REMOVAL

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. DISCONNECT BATTERY NEGATIVE TERMINAL

CAUTION: Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
6. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
7. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY
8. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
a. Install SST on the piping clamp.

SST 09870-00025

HINT: Make sure the direction of the piping clamp and SST by seeing the illustration given on the caution label.

b. Push down SST and release the clamp lock.

NOTE: Do not deform the tube when pushing the SST.

c. Pull the SST slightly and push the release lever, and then remove the piping clamp with SST.

d. Disconnect the air conditioning tube and accessory assembly.

NOTE:
- Do not use tools like a screwdriver to remove the tube.
- Cap the open fittings immediately to keep moisture or dirt out of the system.

e. Remove the 2 O-rings from the air conditioning tube and accessory assembly.

9. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1

SST 09870-00015

HINT: Disconnection of the cooler refrigerant suction hose No.1 is the same as the air conditioning tube and accessory assembly.

10. DISCONNECT HEATER WATER OUTLET HOSE

a. Using pliers, grip the claws of the clip and slide the clip, and then disconnect the heater water outlet hose.

NOTE:
- Do not apply any excessive force to the heater water outlet hose.
- Prepare a drain pan or cloth for cooling water leaks.

11. DISCONNECT HEATER WATER INLET HOSE

HINT: Disconnection of the heater water inlet hose is same as the heater water outlet hose.

12. REMOVE INSTRUMENT PANEL ASSEMBLY

HINT: Refer to the instructions for removal of the instrument panel assembly.

13. REMOVE HYBRID VEHICLE CONTROL ECU
14. REMOVE AIR CONDITIONER AMPLIFIER ASSEMBLY
15. REMOVE AIR DUCT REAR NO.2

a. Turn back the floor carpet.

HINT: Turn back the floor carpet so that the air duct rear No.2 can be removed.

b. Release the claw and remove the air duct rear No.2.

16. REMOVE AIR DUCT REAR NO.1

a. Turn back the floor carpet.

HINT: Turn back the floor carpet so that the air duct rear No.1 can be removed.

b. Release the claw and remove the air duct rear No.1.

17. REMOVE AIR DUCT NO.1

a. Remove the bolt.
b. Release the 3 claws and remove the air duct No.1.

18. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
19. REMOVE SHIFT LEVER
20. REMOVE INSTRUMENT PANEL BRACKET NO.4

a. Remove the 4 nuts and instrument panel bracket No.4.

21. REMOVE INSTRUMENT PANEL BRACE NO.1 SUB-ASSEMBLY

a. Remove the clamp and disconnect the connector.
b. Remove the 3 bolts and 2 nuts and instrument panel brace No.1 sub-assembly.

22. REMOVE INSTRUMENT PANEL BRACE NO.2 SUB-ASSEMBLY

a. Remove the clamp and disconnect the connector.
b. Remove the 3 bolts and 2 nuts and instrument panel brace No.2 sub-assembly.

23. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Manual Tilt Type)
24. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Power Tilt and Power Type)
25. REMOVE STEERING COLUMN ASSEMBLY (Manual Tilt Type)
26. REMOVE STEERING COLUMN ASSEMBLY (Power Tilt and Power Type)
27. REMOVE AIR DUCT NO.1 SUB-ASSEMBLY

a. Remove the 3 nuts and air duct No.1 sub-assembly.

28. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

a. Remove the 4 bolts and 4 nuts.
b. Remove the clamp.
c. Disconnect the connectors.

d. Remove the 9 bolts and the 2 nuts and then remove the instrument panel reinforcement while holding the air conditioner unit assembly.

HINT: Make sure to hold the air conditioner unit assembly securely as its bracket installation parts may be damaged.

29. REMOVE AIR CONDITIONER UNIT ASSEMBLY

a. Remove the 2 nuts and air conditioner unit assembly.

HINT: Make sure to hold the air conditioner unit assembly securely as its bracket installation parts may be damaged.

30. REMOVE AIR DUCT NO.2

a. Remove the screw.
b. Release the 2 claws and remove the air duct No.2.

31. REMOVE WIRING AIR INDICATOR HARNESS NO.2 SUB-ASSEMBLY

a. Remove the 3 screws.
b. Remove the clamp and disconnect the 2 connectors.
c. Remove the wiring air indicator harness No.2 sub-assembly.

32. REMOVE BLOWER ASSEMBLY

a. Remove the screw.
b. Release the claw and remove the blower assembly.

INSTALLATION

1. INSTALL BLOWER ASSEMBLY

a. Engage the claw to install the blower assembly.

2. INSTALL WIRING AIR INDICATOR HARNESS NO.2 SUB-ASSEMBLY

a. Install the wiring air indicator harness No.2 sub-assembly with the 3 screws.
b. Connect the connectors and clamp.

3. INSTALL AIR DUCT NO.2

a. Install the air duct No.2 with the screw.

Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf)

4. TEMPORARILY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY

a. Temporarily tighten the air conditioner unit assembly with the 2 nuts.

HINT: Make sure to hold the air conditioner unit assembly securely as its bracket installation parts may be damaged.

5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

a. Install the instrument panel reinforcement with the 8 bolts.

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

b. Temporarily tighten the air conditioner unit assembly with the 2 nuts and bolt.
c. Install the 4 bolts and 4 nuts.
d. Install the clamps.

e. Connect the connectors.

6. INSTALL INSTRUMENT PANEL BRACE NO.2 SUB-ASSEMBLY

a. Install the instrument panel brace No.2 sub-assembly with the 3 bolts and 2 nuts.
b. Install the clamps and connect the connectors.

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

a. Install the instrument panel brace No.1 sub-assembly with the 3 bolts and 2 nuts.
b. Install the clamps and connect the connectors.

8. INSTALL INSTRUMENT PANEL BRACKET NO.4

9. INSTALL AIR DUCT NO.1 SUB-ASSEMBLY

a. Install the air duct No.1 sub-assembly with the 3 nuts.

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

NOTE: Tighten the bolts in numerical order shown in the illustration to install the air duct No.1 sub-assembly.

10. FULLY TIGHTEN AIR CONDITIONER UNIT ASSEMBLY

a. Fully tighten the air conditioner unit assembly with the 3 bolts and 4 nuts.

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

NOTE:
- Tighten the bolts in numerical order shown the illustration to install the air conditioner unit assembly.
- Install the air conditioner unit assembly so that there is no clearance between the duct and blower assemblies.

11. INSTALL STEERING COLUMN ASSEMBLY (Manual Tilt Type)
12. INSTALL STEERING COLUMN ASSEMBLY (Power Tilt and Power Type)
13. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Manual Tilt Type)
14. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (Power Tilt and Power Type)
15. INSTALL AIR DUCT NO.1

a. Install the air duct No.1 with the bolt.

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

16. INSTALL HYBRID VEHICLE CONTROL ECU
17. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY
18. INSTALL SHIFT LEVER
19. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
20. INSPECT SHIFT LEVER POSITION
21. ADJUST SHIFT LEVER POSITION
22. INSTALL AIR DUCT REAR NO.1
23. INSTALL AIR DUCT REAR NO.2
24. INSTALL INSTRUMENT PANEL ASSEMBLY

HINT: Refer to the installation procedures for the instrument panel assembly.

25. INSTALL HEATER WATER INLET HOSE
26. INSTALL HEATER WATER OUTLET HOSE
27. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1

a. Remove the attached vinyl tape from the hose.
b. Coat a new O-ring with compressor oil and install it to the hose.

Compressor oil:
ND-OIL 11 or equivalent

NOTE:
- Do not use any compressor oil other than ND-OIL 11 or equivalent.
- If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

c. Install the cooler refrigerant suction pipe No.1 and piping clamp.

HINT:
- Be sure to connect the hose securely.
- After connection, check the fitting for the claw of the piping clamp.

28. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
a. Remove the attached vinyl tape from the hose.
b. Coat a new O-ring with compressor oil and install it to the pipe.

Compressor oil:
ND-OIL 11 or equivalent

NOTE:
- Do not use any compressor oil other than ND-OIL 11 or equivalent.
- If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

c. Install the air conditioning tube and accessory assembly and piping clamp.

HINT:
- Be sure to connect the hose securely.
- After connection, check the fitting for the claw of the piping clamp.

29. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY
30. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
32. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
33. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
34. ADD COOLANT (for Engine)
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
36. CHARGE WITH REFRIGERANT
37. WARM UP COMPRESSOR
38. INSPECT FOR COOLANT LEAK (for Engine)
39. INSPECT FOR REFRIGERANT LEAK
40. REMOVE PERFORM INITIALIZATION

NOTE: Some systems need initialization when disconnecting the cable from the negative battery terminal.