Installation
HEATING / AIR CONDITIONING: FRONT AIR CONDITIONING UNIT: INSTALLATION
1. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit with the 3 screws onto the instrument panel reinforcement.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
2. INSTALL INSTRUMENT PANEL REINFORCEMENT
(a) Install the instrument panel reinforcement with air conditioning unit onto the vehicle.
(b) Tighten the 5 bolts as shown in the illustration.
Text in Illustration
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
(c) Install the 2 hole plugs.
(d) Tighten the 3 bolts and nut.
Torque : 19 Nm (189 kgf-cm, 14 ft-lbf) for bolt A
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf) for nut
3. INSTALL INSTRUMENT PANEL WIRE
(a) Engage the clamps and install the instrument panel wire.
(b) Install the ground wire with the bolt.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(c) Connect the connectors.
4. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY
(a) Tighten the 3 nuts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the No. 2 instrument panel brace with the bolt, 2 nuts and screw.
(b) Install the ground wire with the bolt.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(c) Engage the 5 clamps.
(d) Connect the connector.
6. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the No. 1 instrument panel brace with the 2 bolts, 2 nuts and screw.
(b) Install the ground wire with the bolt.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(c) Engage the 5 clamps.
(d) Connect the connector.
7. INSTALL NO. 5 INSTRUMENT PANEL BRACKET
(a) Install the No. 5 instrument panel bracket with the 3 nuts.
(b) Connect the 3 connectors.
HINT
If the vehicle is equipped with USB audio system, connect the connector.
8. INSTALL REAR NO. 2 AIR DUCT
(a) Engage the 2 claws and install the No. 2 air duct.
(b) Install the clip.
9. INSTALL REAR NO. 4 AIR DUCT
HINT
Use the same procedure as for the No. 2 side.
10. INSTALL FRONT FLOOR CARPET ASSEMBLY
Installation
11. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY LH
(a) Temporarily install the front door panel with the 4 bolts to the vehicle.
(b) Pass the front door wire through the opening in the body.
(c) Tighten the 4 bolts on the hinge side.
Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)
(d) Install the front door check with the bolt.
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
12. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY RH
HINT
Use the same procedure as for the No. 2 side.
13. CONNECT FRONT DOOR WIRE LH
(a) Connect the 3 connectors.
14. CONNECT FRONT DOOR WIRE RH
(a) Connect the 3 connectors.
15. INSTALL CENTER AIRBAG SENSOR ASSEMBLY Installation
16. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY Installation
17. INSTALL ECU INTEGRATION BOX RH Installation
18. INSTALL STEERING COLUMN ASSEMBLY
Installation
19. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Engage the 3 claws and install the No. 3 air duct.
(b) Install the clip.
20. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
Installation
21. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
(a) Remove the vinyl tape from air conditioner tube and accessory and the connecting portion of the unit.
(b) Sufficiently apply compressor oil to 2 new O-rings and the connecting part of the air conditioner tube and accessory.
Compressor oil:
ND-OIL8 or equivalent
(c) Install the 2 O-rings onto the air conditioner tube and accessory.
(d) Turn the hook connector in the direction indicated by the arrow in the illustration.
(e) Insert the pipe joints securely into the fitting holes and tighten the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
22. CONNECT HEATER WATER INLET HOSE A (for 2GR-FE)
(a) Install the heater water inlet hose onto the air conditioning unit.
Text in Illustration
HINT
Perform the installation with the hose clip and mark at the correct angle.
23. CONNECT HEATER WATER OUTLET HOSE A (for 2GR-FE)
(a) Install the heater water outlet hose onto the air conditioning unit.
Text in Illustration
HINT
Perform the installation with the hose clip and mark at the correct angle.
24. CONNECT HEATER WATER INLET HOSE A (for 1AR-FE)
(a) Install the heater water inlet hose onto the air conditioning unit.
Text in Illustration
HINT
Perform the installation with the hose clip and mark at the correct angle.
25. CONNECT HEATER WATER OUTLET HOSE A (for 1AR-FE)
(a) Install the heater water outlet hose onto the air conditioning unit.
Text in Illustration
HINT
Perform the installation with the hose clip and mark at the correct angle.
26. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (for 2GR-FE)
Installation
27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
28. ADD ENGINE COOLANT (for 2GR-FE) Service and Repair
29. ADD ENGINE COOLANT (for 1AR-FE) Service and Repair
30. INSPECT FOR COOLANT LEAK (for 2GR-FE) Testing and Inspection
31. INSPECT FOR COOLANT LEAK (for 1AR-FE) Testing and Inspection
32. CHARGE REFRIGERANT Service and Repair
33. WARM UP ENGINE Service and Repair
34. INSPECT FOR REFRIGERANT LEAK Service and Repair
35. INSTALL NO. 1 ENGINE UNDER COVER (for 2GR-FE) Installation
36. INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GR-FE) Installation
37. INSTALL NO. 1 ENGINE UNDER COVER (for 1AR-FE) Installation
38. INSPECT FRONT DOOR PANEL SUB-ASSEMBLY LH
HINT
Use the same procedure as for the RH side Adjustments.
39. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY LH
HINT
Use the same procedure as for the RH side Adjustments.
40. INSPECT FRONT DOOR PANEL SUB-ASSEMBLY RH Adjustments
41. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY RH Adjustments