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WORKSHOP MANUAL

HEATING, VENTILATION
AND AIR CONDITIONING
No.TFHAC-WE-1211TH
2012MY
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0 Introduction
14A Service Information Guide
14B Vehicle Information
1 ENGINE 15B Maintenance Information
15C Functional Inspection
15D Symptom
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1I Speed Control Systems
1J Electrical
2 SUSPENSION 16B Maintenance Information
16C Functional Inspection
16D Symptom
2B Front Suspension
2C Rear Suspension
2D Wheel, Tire System
3 DRIVELINE, AXLE 17B Maintenance Information
17C Functional Inspection
17D Symptom
17E DTC Information
3A Driveline Control
3B Differentials
3C Drive Shaft System
3D Transfer Case
4 BRAKES 18B Maintenance Information
18C Functional Inspection
18D Symptom
18E DTC Information
4A Brake Control
4B Brake System
4C Parking Brake System
4D ABS
5 TRANSMISSION, TRANSAXLE 19B Maintenance Information
19C Functional Inspection
19D Symptom
19E DTC Information
5A Transmission Control
5B Automatic
5C Manual
5E Clutch System
6 STEERING 20B Maintenance Information
20C Functional Inspection
20D Symptom
6B Power Assisted System
67209_Maegaki 2011.7.22 0:48 PM . 1
Section Sub Section
7 HVAC 21B Maintenance Information
21C Functional Inspection
21D Symptom
7B Heater, Ventilator, Airconditioner
8 RESTRAINTS 22B Maintenance Information
22C Functional Inspection
22D Symptom
22E DTC Information
8A SRS Control
8B Air Bag Systems
8C Seat Belt Systems
9 BODY, CAB, ACCESSORIES 23B Maintenance Information
23C Functional Inspection
23D Symptom
9A Lighting Systems
9B Wiper, Washer Systems
9C Electrical Control, Entertainment
9E Instrumentation, Driver Info.
9G Hood, Fenders, Doors
9H Cab Structure
9I Seats
9J Security and Locks
9L Exterior, Interior Trim
9P Unibody Sub-frames
9T Glass, Windows, Mirrors
10 BODY CONTROL 36B Maintenance Information
36C Functional Inspection
36D Symptom
36E DTC Information
10I Body Control
10 SECURITY AND LOCKS CONTROL 42B Maintenance Information
42C Functional Inspection
42E DTC Information
10S Security and Locks Control
11 FRAME 24B Maintenance Information
- ETM - Using the Wiring Diagram
- Power System
- Engine
- Chassis
- Brake
- Safety
- Driver Assist
- Accessory
- Light
- Data Communications
- Location Diagram
- Connector List
67209_Maegaki 2011.7.22 0:48 PM . 2
Description HVAC
Maintenance Information
(All models)
Table of Contents
Maintenance precautions of heating, ventilation air
conditioning...................................................................21B-2
Function, structure, operation of heating, ventilation air
conditioning...................................................................21B-5
Primary specifications of heating, ventilation air
conditioning.................................................................21B-30
Introduction to the trouble diagnosis of heating, ventilation
air conditioning............................................................21B-31
Maintenance Information (All models) 21B-1
Maintenance precautions of heating, ventilation air conditioning
1. Maintenance precautions of heating, ventilation air
conditioning
Caution
Make sure to keep the work area clean at all
times.
Always wear protective goggles when
performing work on the A/C system.
Be careful of carbon monoxide emissions or
discharge of refrigerant gas when starting the
engine in a closed area or a poorly ventilated
garage.
Before replacing or repairing the A/C system,
always disconnect the battery negative
terminal and drain the refrigerant.
Use a recovery device when draining the
refrigerant.
Pay attention to moisture and dust.
Block the opening with a plug or a cap
immediately after removing the refrigerant
piping or parts, and do not remove the plug or
a cap until the piping or part is connected or
installed again.
When removing or reconnecting the piping,
support the connection with a backup wrench
to prevent it from being twisted or damaged.
Apply new compressor oil to the O-ring before
connecting a hose or a pipe.
When removing or replacing parts which
require removing the refrigerant from the A/C
system, perform the following procedures:
remove the refrigerant from the A/C system,
remove and replace the defective parts, and
then perform vacuuming and fill the A/C
system with the refrigerant up to the specified
level.
Refrigerant leakage repair and refrigerant pipe connection
Be sure to install a new O-ring when connecting the
removed refrigerant pipe. When removing or connecting
the piping, use a backup wrench to prevent the
connection from being twisted or damaged.
1. Backup wrench
2. Torque wrench
When connecting the refrigerant pipe at the block joint
section, fit the convex section of the joint section firmly
into the connection hole of the unit and secure it with a
bolt.
1. Block joint
Apply compressor oil to the O-ring before connecting.
Since compressor oil is different depending on the
compressor type, be sure to use the compressor oil that
matches the compressor type.
21B-2 Maintenance Information (All models)
1. Oil applying area
2. O-ring
Securely insert the O-ring into the groove of the
refrigerant pipe.
1. O-ring
Insert the pipe into the union. First tighten the nut with
your hand as much as possible. Then, tighten the nut to
the specified torque.
1. Nut
2. Union
Leakage at the refrigerant pipe connection
Check the torque of the connecting parts for the
refrigerant pipe, and tighten them to the specified torque
if they are loose. When doing so, use a backup wrench to
prevent the piping from becoming twisted or damaged.
Also, do not over-tighten.
Inspect for leakage from the connecting parts of the
refrigerant pipe.
If leakage is found, drain the refrigerant from the A/C
system.
Inspect the O-ring and replace it if necessary. In this case,
do not reuse the O-ring. Be sure to replace it with a new
one.
Be sure to apply compressor oil to the new O-ring before
connecting.
Tighten the connecting parts of the refrigerant pipe to the
specified torque. Use a backup wrench to prevent the
piping from becoming twisted or damaged.
Perform vacuuming, fill the refrigerant and check the A/C
system.
Leakage from the hose
When refrigerant is leaking from the inlet or outlet side
hose of the compressor, replace the entire hose. Do not
cut the hose or connect hoses.
Locate the area where refrigerant is leaking.
Drain the refrigerant.
Remove the hose assembly. After disconnecting the hose,
put a cap or a cover on the connection to prevent foreign
material from entering the A/C cycle.
Install a new hose assembly on the compressor. Tighten
the connecting parts of the hose to the specified torque.
Perform vacuuming, fill the refrigerant and check the A/C
system.
Leakage from the compressor
Maintenance Information (All models) 21B-3
When compressor oil is leaking from the shaft seal or the
shell, etc. of the compressor, replace the compressor
assembly.
Handling of the refrigerant
The refrigerant circulates in the A/C system. It is a
chemical product which requires special handling
procedures in order to prevent accidents caused by
mishandling.
When installing/removing or replacing the A/C cycle
parts, be sure to wear goggles and put a cap or a cover on
the connection of the refrigerant pipe or the unit.
Perform the work in a well ventilated area. Do not
perform welding or steam cleaning on the A/C piping or
unit installed in a vehicle.
If you get the refrigerant on your body, wash with water
and seek medical treatment.
When there is a need to move the refrigerant from a large
container to a small one, do not fill the container all the
way. Take the expansion of the refrigerant into
consideration and be sure to secure room for it in the
container.
Store the refrigerant container at a temperature of 40 C
{104 F} or lower.
21B-4 Maintenance Information (All models)
Function, structure, operation of heating, ventilation air conditioning
1. Function, structure, operation of heating, ventilation air
conditioning
The inside/outside air change lever of the manual A/C, or
the outside air intake/inside air recirculation switch of the
auto A/C is used for selecting outside air intake or inside
air recirculation. When it is set to "FRESH", the outside
air is always taken inside.
Control lever assembly
The fan control regulates the outlet air volume in 4 levels
from "LOW" to "HIGH" according to the blower resistor.
1. Rear window defogger switch
2. Fan speed control dial
3. Temperature adjustment dial
4. Air selector lever
5. Outlet selector dial
Control panel assembly
The control panel assembly performs blow outlet
selection, temperature adjustment of the heater unit and
inside/outside air change of the blower assembly
according to the actuator. The fan control regulates the
outlet air volume in 4 levels according to the blower
module assembly in the manual mode.
Maintenance Information (All models) 21B-5
1. OFF switch
2. A/C switch
3. AUTO switch
4. Display panel indication
5. Fan speed control switch
6. Windshield defroster switch
7. Outside air intake switch
8. Inside air recirculation switch
9. Rear window defogger switch
10. Temperature adjustment dial
11. Outlet selector switch (MODE switch)
Fan speed control switch (Auto cooler)
The blower motor rotation is controlled by this switch via
the blower module to adjust the amount of air blow from
the air outlet.
There are the following 5 setting positions for the switch.
LOW
MEDIUM LOW
MEDIUM
MEDIUM HIGH
HIGH
Fan dial (Manual cooler)
The fan dial controls the rotation of the blower motor in 4
levels via the blower motor assembly in the manual
mode.
Inside/outside air change lever (Manual)
By sliding this lever to the left or right, switching
between "FRESH" and "RECIRC" can be performed.
Inside air recirculation switch (Auto)
When this switch is pressed, it is switched to "RECIRC".
Outside air intake switch (Auto)
Pressing this switch switches to "FRESH".
21B-6 Maintenance Information (All models)
Ventilation (Manual)
When the inside/outside air change lever is set to
"FRESH", the outside air is always taken inside.
The blower fan has a function to maintain proper
ventilation by taking the outside air into the vehicle
cabin.
When the inside/outside air change lever is set to
"RECIRC", the inside air is recirculated without taking in
the outside air.
Ventilation (Auto)
When the outside air intake switch is pressed, the outside
air is taken inside at all times.
The blower fan has a function to maintain proper
ventilation by taking the outside air into the vehicle
cabin.
When the inside air recirculation switch is pressed, the
inside air is recirculated at all times without taking in the
outside air.
1. Intake door
2. Blower fan
3. Blower motor
Outlet selector dial (Manual)
The outlet to send the air can be selected by this dial.
The air outlet to send air is selected by adjusting the
position of the rotary type mode door located inside the
heater unit. This mode door adjusts the opening range of
each outlet of the heater unit and blocks the opening
sections, enabling selection of 3 blowing patterns.
Outlet selector switch (MODE switch) (Auto)
The outlet to send the air can be selected by this switch.
The air outlet to send air is selected by adjusting the
position of the rotary type mode door located inside the
heater unit. This mode door adjusts the opening range of
each outlet of the heater unit and blocks the opening
sections, enabling selection of 5 blowing patterns.
Maintenance Information (All models) 21B-7
"DEFROST" can be selected by pressing the defroster
switch. The A/C automatically turns ON when the
defroster switch is pressed.
FACE (Auto)
At this position, the air is supplied into the vehicle cabin
through the ventilation ducts 1 and 2.
The amount of air is controlled by the fan switch knob.
FACE (Manual)
At this position, the air is supplied into the vehicle cabin
through the ventilation ducts 1 and 2.
The amount of air is controlled by the fan dial.
BI-LEVEL
At this position, the air is divided into two groups in the
heater unit, and supplied to the vehicle cabin through the
ventilation ducts 1 and 2 and the foot duct 5.
FOOT
At this position, the entire amount of air is supplied to the
feet through the foot duct 5.
DEF/FOOT
At this position, the air is divided into two groups in the
heater unit, and blown in through the defroster nozzles 3
and 4 and the foot duct 5.
DEFROST (Auto)
At this position, a large proportion of the air is supplied
to the front window 4, and a small amount of the air is
supplied to the side window 3.
Note
Mode door operation diagram
21B-8 Maintenance Information (All models)
1. Mode door, for DEF
2. Evaporator core
3. Mode door, for FOOT
4. Mode door, for FACE
Note
Mode door structural diagram, BI-LEVEL mode
Maintenance Information (All models) 21B-9
1. Mode door, for DEF
2. Evaporator core
3. Mode door, for FOOT
4. Mode door, for FACE
Temperature adjustment knob (Manual)
Cooling intensity adjustment from MAX COLD to MIN
COLD is available by adjusting the temperature of air
blown from the air outlet with this knob.
Temperature adjustment dial (Auto)
Cooling intensity adjustment from MAX COLD to MIN
COLD is available by adjusting the temperature of the air
blown from the air outlet using this dial.
Note
When set to "MAX COLD", FACE mode
21B-10 Maintenance Information (All models)
1. Mode door, for DEF
2. Evaporator core
3. Mode door, for FOOT
4. Mode door, for FACE
Manual A/C
The manual A/C in this vehicle is comprised of a
compressor, evaporator, condenser, fan switch, etc.
The A/C is started when the fan switch is turned ON and
the magnetic clutch is engaged at the engine startup.
Also, it stops operating when the fan switch is turned
OFF.
Besides this switch, there are functions to temporarily cut
off the A/C by the system in the A/C cycle. Such
functions include detection of an abnormal refrigerant
pressure by the pressure switch, detection of the outlet air
blow temperature by the thermo switch for preventing
freezing of the evaporator core, and detection of the
engine water temperature by the thermo switch set in
some vehicle types.
A/C cycle
The A/C cycle has 4 functions described below. The
refrigerant is circulating while repeatedly changing its
state from liquid to gas then to liquid.
1. Compressor
2. Magnetic clutch
3. Pressure switch
4. Condenser, integrated with receiver dryer
5. Evaporator assembly
6. Expansion valve
7. Evaporator core
8. Blower motor
9. Ventilation unit
10. Mode (DEF/FOOT) control door
Maintenance Information (All models) 21B-11
11. Mode (VENT) control door 12. Electronic thermostat
Evaporation
The refrigerant changes its state from liquid to gas inside
the evaporator.
The refrigerant in the mist form evaporates immediately
after it enters the evaporator. When the refrigerant
evaporates, it steals heat from the air around the
evaporator core cooling fin. The air that has lost heat is
cooled down and sent into the vehicle by the blower fan
to lower the vehicle room temperature.
The refrigerant liquid sent from the expansion valve and
the evaporated refrigerant gas coexist in the evaporator,
and the refrigerant changes its state from liquid to gas.
During this state change from liquid to gas, the pressure
inside the evaporator has to be kept low for the
refrigerant to evaporate in lower temperature. To do so,
the refrigerant gas is sucked into the compressor and
discharged to the outside of the evaporator.
Compression
The refrigerant is compressed by the compressor to the
state where it is easy to liquefy at room temperature.
The vaporized refrigerant in the evaporator is sucked into
the compressor. This function maintains the refrigerant in
the evaporator at low pressure and keeps the liquid
refrigerant to evaporate even at a low temperature close
to 0 C {32 F}. The refrigerant that is sucked into the
compressor is compressed inside the cylinder. Its pressure
is raised so that it is easily liquefied by the outside air at
room temperature.
Condensation
The refrigerant inside the condenser is cooled down by
the outside air and changes its state from gas to liquid.
The high temperature and high pressure gas from the
compressor is cooled down and liquefied by the
condenser and the outside air, and collected in the
receiver dryer. The heat that is dissipated by the high
temperature and high pressure refrigerant from the
compressor to the outside air is known as condensing
heat. This heat quantity is the sum of the heat taken by
the refrigerant from inside the vehicle via the evaporator
and the work performed during compression.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it evaporates easily.
The process where the pressure is lowered to ease
evaporation before the liquefied refrigerant is sent to the
evaporator is known as expansion. The expansion valve
also controls the flow amount of the refrigerant liquid
while lowering its pressure. In other words, since the
amount of the refrigerant liquid to be evaporated inside
the evaporator is determined by the amount of the heat
taken at a given evaporating temperature, it is important
to control the amount of the refrigerant so that it is not
less or more than the necessary amount.
Compressor
The compressor compresses the low pressure and low
temperature refrigerant vapor from the evaporator into a
high pressure and high temperature refrigerant vapor, and
sends it to the condenser to ease dissipation of heat to the
outside air.
The vane rotary type fixed capacity compressor CR12Sb,
manufactured by Calsonic Kansei, features a simple
structure, lightweight compact size and superior
mountability.
Also, the number of components used is reduced,
resulting in excellent cost performance. As for noise, 10
discharges are made per rotation, so the flow of the
refrigerant is smooth, and it is quiet because the
fluctuation in torque is small.
The specified oil amount is 150 cm3.
21B-12 Maintenance Information (All models)
1. Compressor
Magnetic clutch
The compressor is driven by the drive belt from the
engine crank pulley. It is, however, not desirable for the
compressor to be driven each time the engine is started
because it imposes a significant load on the engine.
Therefore, the magnetic clutch transmits the power from
the engine when the A/C is ON to activate the
compressor. It stops the power transmission from the
engine when the A/C is turned OFF.
Maintenance Information (All models) 21B-13
1. Magnetic clutch
Condenser
The condenser forces the high temperature and high
pressure refrigerant gas sent from the compressor to be
cooled down by the outside air and liquefied. If the
condenser is clogged or the air flow into the condenser
cooling fin is blocked, it will cause an insufficient
cooling capacity of the condenser and an increased load
on the engine due to the raised pressure of the refrigerant
cycle. When the condenser is operated normally, the
refrigerant discharge line of the condenser is usually
cooler than the intake line.
An electric fan is also equipped to boost the cooling
effect.
1. Condenser assembly, integrated with receiver
dryer
Receiver dryer
The receiver dryer has the following functions.
The amount of the circulating refrigerant varies
depending on the conditions of the A/C cycle, so it stores
the necessary amount of the refrigerant for the A/C cycle
21B-14 Maintenance Information (All models)
to operate smoothly in accordance with changes in the
circulating amount.
Bubbles of the refrigerant gas are included in the
liquefied refrigerant from the condenser. If refrigerant
including bubbles are sent to the expansion valve, the
cooling capacity may become significantly deteriorated.
Therefore, it separates the liquid from the bubbles and
sends only the liquid to the expansion valve.
The dust and water included in the circulating refrigerant
are removed using the filter and the dryer inside the
receiver dryer.
Clogging in the receiver dryer may cause the A/C's
performance to deteriorate. When clogging occurs at the
inlet of the receiver dryer, the refrigerant pressure rises,
while the pressure lowers when clogging occurs at the
outlet. In both cases, cooling can barely take place. If the
pipe at the outlet of the receiver dryer is unusually cold,
this indicates that clogging has occurred.
Pressure switch
The pressure switch is installed in the high pressure pipe.
The high pressure switch monitors the refrigerant for an
abnormally high pressure. The low pressure switch
monitors for refrigerant leakage to prevent compressor
seizure, turning the magnetic clutch on or off at each
preset pressure value.
1. Condenser assembly
2. Refrigerant piping
3. Pressure switch
Item Pressure switch
Control
pressure
Low pressure control, low pressure switch High pressure control, high pressure switch
Operation Compressor Compressor
ON 176 to 216 kPa { 1.8 to 2.2 kgf/cm2 / 26 to 31 psi }
2840 to 3040 kPa { 29.0 to 31.0 kgf/cm2 / 412 to
441 psi }
OFF 195 to 255 kPa { 2.0 to 2.6 kgf/cm2 / 28 to 37 psi }
100 - 200 kPa lower pressure than "ON" operation
pressure
Evaporator
The evaporator changes the low pressure and low
temperature atomized liquid refrigerant sent from the
expansion valve into gas by exchanging heat with air sent
from the blower motor. The vaporization heat that is
generated when the liquid refrigerant evaporates into gas
cools down the evaporator and the evaporator core fin,
and then cools down air sent from the blower motor.
Moisture in air is cooled and forms water droplets, and
the vehicle is dehumidified by removing these droplets
from the vehicle.
Expansion valve
The expansion valve is a uniform external pressure type
and is installed in the inlet of the evaporator core.
The high pressure liquid refrigerant sent from the receiver
dryer undergoes a squeezing action when it passes
through the expansion valve, which changes it into a low
pressure liquid refrigerant in mist form before it is sent to
the evaporator core.
This expansion valve is comprised of a thermosensor,
diaphragm, ball valve, spring adjustment screw, etc. The
thermosensor contacts the evaporator outlet pipe and
controls the refrigerant flow amount by converting the
temperature variation into pressure to operate the
diaphragm.
The expansion valve can also be used to adjust the
refrigerant flow amount as it ensures efficient capacity
utilization of each device of the A/C cycle. Therefore,
abnormalities in the expansion valve will cause both the
outlet pressure and the inlet pressure values to drop,
resulting in the evaporator having insufficient cooling.
Maintenance Information (All models) 21B-15
1. Evaporator core
2. Expansion valve
Thermo switch
The thermo switch utilizes an amplifier and a thermistor
to reduce the operating noise, etc.
The fin sensor is installed on the outlet of the evaporator
core, and detects the temperature of the air that passes the
evaporator core.
The OFF value is 2.7 C {36.9 F}, and the ON value is
6.2 C {43.2 F}.
1. Evaporator core
2. Fin sensor
3. Heater and evaporator unit assembly
Refrigerant pipe
The following phenomena are observed if clogging
occurs in the refrigerant pipe.
Low pressure hose
When clogging occurs in the low pressure hose, the
compressor's inlet pressure and the outlet pressure drop,
and the cooling capacity is lost.
High pressure hose
When clogging occurs in the high pressure hose, a
leakage from the outlet line usually occurs.
High pressure pipe
When clogging occurs in the high pressure pipe, the
pressures at both of the outlet and the inlet sides drop,
resulting in insufficient cooling.
The high and low pressure flexible hoses are low leakage-
type hoses that are equipped with a nylon coating at the
innermost of the hoses.
It is also designed to prevent refrigerant leakage to the air
when connecting a service tool by enabling quick
connection of the service tool.
1. Polyester
2. Exterior rubber layer
3. Interior rubber layer
4. Nylon layer
Full-auto A/C
This full-auto A/C uses various sensors to accurately
detect the outside temperature, the amount of solar
radiation received, the blowing temperature of the
evaporator, the water temperature of the viscous coupling
unit and the in-vehicle temperature. The detected
information is input to the auto A/C control unit to
automatically control the blowing temperature, blowing
amount, ON-OFF switch of the compressor, outlets
switching, etc. Also, each auto-control can be manually
controlled by deactivating the auto function.
This auto A/C control unit with a built-in micro-computer
is equipped with a self-diagnosing function to make it
easier to access and to diagnose areas where there is
trouble.
21B-16 Maintenance Information (All models)
Maintenance Information (All models) 21B-17
Note
Control panel
1. OFF switch
2. A/C switch
3. AUTO switch
4. Display panel indication
5. Fan speed control switch
6. Windshield defroster switch
7. Outside air intake switch
8. Inside air recirculation switch
9. Rear window defogger switch
10. Temperature adjustment dial
11. Outlet selector switch (MODE switch)
Note
Control panel switch operations and general
functions
21B-18 Maintenance Information (All models)
Maintenance Information (All models) 21B-19
Note
Control panel switch operations and general
functions
21B-20 Maintenance Information (All models)
Full-auto A/C control unit A large LCD panel is utilized to improve visibility by
displaying the operating status of the full-auto A/C. Also,
Maintenance Information (All models) 21B-21
the set temperatures are displayed in digital format, and
the setting can be made in 1 C {1.8 F} increments.
Automatic room temperature control
Maintains the in-vehicle temperature at a temperature set
using the temperature control switch regardless of
changes in the vehicle speed, outside air temperature,
sunlight conditions, number of passengers, etc.
Air amount auto control
Automatically controls the air blow amount in a
continuous and sensitive manner according to the changes
in the in-vehicle setting temperature.
Mode control
The mode control automatically switches the mode to
FACE, BI-LEVEL or FOOT according to changes in the
blow outlet temperature etc. The blow outlet can be
manually selected by operating the mode switch.
However, only manual selection is available for DEF/
FOOT.
Cooling startup control
When starting the vehicle in a high room temperature
during summer, etc., it locks the air volume to "OFF"
until the evaporator cools in order to prevent a large
amount of hot air from blowing into the vehicle cabin.
Heater startup control
When starting the vehicle in a low room temperature
during winter, etc., it fixes the air volume to "OFF" and
sets the mode to "DEFROST" until the water temperature
in the viscous coupling unit warms up to prevent a large
amount of cold air from blowing into the vehicle cabin.
Sunlight condition correction control
The sun sensor utilizes a photodiode to accurately detect
the amount of sunlight and quickly correct the in-vehicle
temperature.
Memory when the ignition is OFF
The switch status before the ignition is turned OFF is
memorized, making it easier to set when restarted.
Self-diagnosis function
The self-diagnosing function is activated by turning on
the self-diagnosing function on using the panel switch.
This makes it easier to conduct trouble diagnosis.
Outside air temperature display
Through the panel switch operations, the outside air
temperature detected by the outside air temperature
sensor is indicated in digital format on the panel display
section.
Inside and outside air temperature sensors
Inside and outside air temperature sensors are installed to
detect changes in the temperatures inside and outside the
vehicle.
These sensors are thermistors whose resistance value
changes according to temperature changes. Room
temperature correction signals for the changes in
resistance value are input to the auto A/C control unit.
As the temperature of the thermistor rises, the resistance
value lowers. Conversely, as the temperature drops, the
resistance value increase.
Inside air temperature sensor
The inside air temperature sensor is a sensor that detects
the temperature in the vehicle and converts the in-vehicle
temperature into a resistance value to input to the auto A/
C control unit. The inside air temperature sensor uses an
aspirator to take in the air while the blower motor is
running and blows the air inside the vehicle to the area
around the sensor.
This sensor is installed on the back side of the knee
bolster panel on the driver's side.
1. Inside air temperature sensor
2. Back side of the knee bolster panel
Outside air temperature sensor
The outside air temperature sensor is a sensor that detects
the temperature outside of the vehicle and converts the
outside temperature into a resistance value to input to the
auto A/C control unit.
Also, an auto-amp determines any heat effect caused by
the condenser or radiator during idling after driving and
makes any necessary corrections. However, the
temperature to be displayed rises over time.
This sensor is installed on the bottom portion of the front
end engine hood stay located at the backside of the
radiator grille.
21B-22 Maintenance Information (All models)
1. Outside air temperature sensor
2. Front bumper assembly
Sun sensor
The sun sensor uses a photodiode to detect the amount of
sunlight. It converts the correction signal from changes in
the in-vehicle temperature caused by sunlight into a
photo-electric current to input to the auto A/C control
unit.
This sensor is installed at the top of the instrument panel
on the driver's side.
1. Sun sensor
2. Instrument panel upper cover
3. Instrument panel
Blower module assembly
The blower module assembly receives a base current
from the auto A/C control unit for variable changing of
the speed of the blower motor.
The blower module assembly is installed in the blower
assembly.
1. Blower assembly
2. Blower module assembly
Actuator
The actuator (has a built-in compact motor) and drives
the mode doors of the heater and blower unit using the
output current from the auto A/C control unit.
The actuator has a mode actuator that switches the mode
of the heater unit and an intake actuator that switches the
intake of the blower unit.
Maintenance Information (All models) 21B-23
1. Mode actuator 2. Intake actuator
Configuration chart of the full-auto A/C system
This system inputs signals to the auto A/C control unit
from each sensor that detect the ambient temperatures
inside and outside the vehicle; the water temperature
sensor that detects the engine water temperature; the fin
sensor that detects refrigerant temperature; the sun sensor
that detects the amount of solar radiation, and operating
signals of the control panel, position detection signals of
the potentiometer, and automatically controls the air mix
door opening, fan speed and the mode door opening by
conversion in the control unit.
21B-24 Maintenance Information (All models)
Overview of the full-auto A/C auto control
The automatic controls for auto A/C are as follows.
Room temperature control
Air amount control
Heater startup control
Cool startup control
Blow outlet control
Room temperature control
The auto A/C control unit calculates using the
temperature setting signals and the signals from each
sensor for the total signal. Then, it compares that with the
signal from the potentiometer to determine the direction
of the mix actuator rotation. The mix actuator opens the
air mix door at the predetermined angle for that total
signal to control the temperature in a vehicle.
Air amount control
The auto A/C control unit calculates using the
temperature setting signal and the signals from each
sensor to find the total signal. Then, according to the total
signal, it converts the blower module assembly base
potential to a predetermined blower voltage for variable
speed operation of the blower motor.
When operating in manual, the fan switch has 5 levels
from LO to MAX HI for setting the air amount.
Cool startup control
When starting the auto A/C with the blow mode set to
FACE and BI-LEVEL and the A/C switch turned to ON,
the auto A/C control unit performs cooling startup control
if the blowing temperature calculated by the auto A/C
control unit is within a certain condition.
For 2 seconds after the cooling starts, this is fixed at
"OFF", then for 5 seconds after that, it is fixed at "LO".
For 6 seconds after that, it increases linearly from "LO"
to the target air amount.
This control is performed only at one time when the
blower motor starts by turning the ignition switch from
"OFF" to "ON" or using the AUTO switch.
Maintenance Information (All models) 21B-25
Blow outlet control
The auto A/C control unit uses the temperature setting
signal and the signals from each sensor to calculate the
total signal. Then, it compares with the signal from the
potentiometer to determine the operating angle of the
mode actuator. The mode actuator operates the mode
door according to the total signal to a predetermined
angle to control the blow outlet to FACE, BI-LEVEL or
FOOT.
Note
Heater, ventilator system components location
diagram
1. Defroster nozzle 2. Side defroster nozzle, right
21B-26 Maintenance Information (All models)
3. Ventilation duct, right
4. Ventilation duct, center
5. Control lever assembly
6. Heater and evaporator unit
7. Blower assembly
8. Ventilation duct, left
9. Side defroster nozzle, left
Note
Manual A/C components location diagram
1. Compressor bracket
2. Compressor
3. Low pressure pipe
4. Heater and evaporator unit assembly
5. High pressure pipe
6. Pressure switch
7. High pressure hose
8. Condenser assembly, integrated with receiver
dryer
9. Outside air temperature sensor
Note
Auto A/C components location diagram
Maintenance Information (All models) 21B-27
1. Compressor bracket
2. Compressor
3. Low pressure pipe
4. Heater and evaporator unit assembly
5. High pressure pipe
6. Pressure switch
7. High pressure hose
8. Condenser assembly, integrated with receiver
dryer
9. Outside air temperature sensor
Note
Auto A/C components location diagram
21B-28 Maintenance Information (All models)
1. Control panel assembly, auto A/C control unit
2. Sun sensor
3. Inside air temperature sensor
4. Heater and evaporator unit assembly
5. Mode actuator
6. Intake actuator
7. Blower module assembly
8. Blower assembly
Maintenance Information (All models) 21B-29
Primary specifications of heating, ventilation air conditioning
1. Primary specifications of heating, ventilation air
conditioning
Note
Primary specifications of the heater, ventilator
and A/C
Item Specifications
Evaporator assembly
Cooling control system Vapor compression method
Heat discharge 5.14 kW (4420kcal/h)
Air supply 500 m3/h
Evaporator core
Model Laminate louver fin
Effective core
dimensions
305 x 265 x 40mm (12.0 x 10.4 x 1.6in)
Expansion valve Model Uniform external pressure
Thermo switch
Applicable only to manual A/C
The auto A/C controls via the control unit
based on the signals from the fin sensor.
Model Electric type, electronic thermostat
Operating temperature
OFF, 2.7 (36.9F)
ON, 6.2 (43.2F)
Condenser
Model MF type sub-cooling model
Heat discharge 18.4 kW (15824kcal/h)
Receiver dryer
Absorbent Synthetic zeolite 40 (1.4oz)
Content 190cm3 (5.4 lmp fl oz)
Pressure switch Operating pressure
Low pressure control
ON, 176 - 216 kPa {1.8 - 2.2 kgf/cm2 / 26 - 31 psi}
OFF, 195 - 255 kPa {2.0 - 2.6 kgf/cm2 / 28 - 37 psi}
High pressure control
ON, 2,840 - 3,040 kPa {29.0 - 31.0 kgf/cm2 / 412 -
441 psi}
OFF, 100 - 200 kPa lower pressure than "ON"
operation pressure
Refrigerant filling quantity HFC-134a 480 - 580g {1.1 - 1.3 lb}
Compressor
Model CR12Sb
Type Vane rotary type
Discharge amount 110cm3 (3.1 lmp fl oz)
Maximum RPM 7000 r/min , Instantaneous 8,500 r/min
Weight 2.63kg {5.8 lb}
Magnetic clutch
Rated voltage 12 V
Power consumption 46 W
Static transfer torque
34 Nm or more { 3.5 kgfm or more / 25 lbft
or more }
Weight 2.1 kg { 4.6 lb }
Specified compressor oil quantity DH-PR 150 cm3 (4.2 lmp fl oz)
Temperature control, auto
A/C
Inside air temperature sensor Resistance 2.2 k , 25 (77F)
Outside air temperature sensor Resistance 1.7 k , 25 (77F)
Sun sensor Photodiode
Control
device
Auto A/C control unit Built-in microcomputer
Actuator
Intake actuator
Mode actuator
Cooling system Vapor compression type
21B-30 Maintenance Information (All models)
Introduction to the trouble diagnosis of heating, ventilation air conditioning
1. Introduction to the trouble diagnosis of heating,
ventilation air conditioning
Trouble diagnosis overview and procedure
This auto A/C is equipped with a self-diagnosis function
to perform inspections on the main components.
This makes it easier to operate inspections for each sensor
and actuator. After identifying the defective areas with
the self-diagnosis function, inspect and repair the
defective areas respectively.
In performing trouble diagnosis, focus on the damaged
parts, and inspect related components. In addition to the
self-diagnosis, inspect the related parts from the
inspection of the damaged parts by accurately identifying
the defect phenomenon for parts that could not be
identified in the self-diagnosis.
Note that before inspecting equipment, confirm that the
connectors are securely connected.
The basic flow of the procedure for trouble diagnosis is
as follows:
Self-diagnosis function Transition to or cancellation of the self-diagnosis function
is performed by the operations indicated below.
Maintenance Information (All models) 21B-31
Failure conditions include current failures, which are
routine failures, such as sensor open circuits and short
circuits and past failures caused by improper connector
connections, etc.
21B-32 Maintenance Information (All models)
A current failure is detected when the current input value
for each code meets a certain judgment level, and is
cancelled when the input value returns to normal.
A past failure is detected when the input value for each
code meets both the judgment level and the judgment
time.
The memory of past failures is erased by removing the
battery negative terminal, so be careful not to remove it
when shifting to trouble diagnosis.
Note
Self-diagnosis operating procedure
Maintenance Information (All models) 21B-33
21B-34 Maintenance Information (All models)
Maintenance Information (All models) 21B-35
21B-36 Maintenance Information (All models)
Inspection of trouble areas When an error is found in the sensors by the self-
diagnosis function, inspect the sensors according to the
following flow.
Maintenance Information (All models) 21B-37
Description HVAC
Functional Inspection
(All models)
Table of Contents
Air conditioning system check......................................21C-2
Checking the air conditioning system using the manifold
gauge.............................................................................21C-4
Automatic air conditioning control unit power circuit
inspection.......................................................................21C-6
Functional Inspection (All models) 21C-1
Air conditioning system check
1. Air conditioning system check inspection
1. Fully close the vehicle doors and operate the air
conditioner with the inside/outside air switch at
RECIRC position, and then sets the highest value to
the fan switch with the temperature adjustment at
MAX COOL.
Note
Maintain this state for a few minutes to
circulate the refrigerant in the air conditioning
cycle.
2. Check the high and low pressure of the refrigerant
with the manifold gauge.
Heating temperature 30 to 35 { 86 to 95 F }
Low pressure side 127 to 245 kPa { 1.30 to 2.50 kgf/
cm2 }
High pressure side 1373 to 1667 kPa { 14 to 17 kgf/
cm2 }
Note
If the high and low pressures are largely
different from the reference pressure values,
refer to checking the air conditioning system
using the manifold gauge to check the system.
Checking the air conditioning system using the manifold
gauge
3. In addition to refrigerant pressures, check also
whether the refrigerant is properly filled using the
sight glass.
Check the sight glass under the following conditions.
Outside temperature is 35C {95F} or lower
Engine rpm is 1500 r/min
Air conditioner switch ON
Inside/outside air change is RECIRC
Fan switch is HIGH
Temperature adjustment is MAX COOL
Pressure at high pressure side is 1667 kPa {17 kgf/cm2}
or lower
Note
If the outside air temperature or the high
pressure side pressure is higher than the
values indicated in the illustration, the
HFC-134a refrigerant may appear cloudy
when checking its status through the sight
glass, which prevents correct judgement.
When this occurs, move the vehicle to a
shaded area or indoors, set the fan switch to
"LO", and lower the load of the air conditioner
so that the air temperature and the high
pressure side pressure are below the values
and then perform the check again.
21C-2 Functional Inspection (All models)
4. Put your hand at the air outlet to check whether the
temperature at which the air is blowing out
corresponds with the temperature set.
5. After completing the system inspection, remove the
charging hose from the service charge valve.
Functional Inspection (All models) 21C-3
Checking the air conditioning system using the manifold gauge
1. Checking the air conditioning system using the
manifold gauge inspection
Inspection conditions
Ambient temperature of surroundings about 30 - 35C
{86 - 95F}
Engine rpm about 1500 r/min
Air conditioner switch ON
Blower motor HIGH
Temperature setting MAX COOL
Close all doors RECIRC
Normal pressure (reference)
The low pressure side is at about 127 - 245 kPa (1.3 - 2.5
kgf/cm2)
The high pressure side is at about 1373 - 1667 kPa (14.0 -
17.0 kgf/cm2)
Manifold gauge connection
Inlet side for low pressure hose
Outlet side for high pressure hose
AS HFC-134a is employed in the air conditioner system
of this vehicle when checking the air conditioner system,
make sure to use air conditioner servicing tools, such as
manifold gauge and charging hose, that are intended for
use with HFC-134a.
1. Low pressure side 2. High pressure side
Symptom
Insufficient cooling
Both the high- and low-pressure values are low
Low pressure side about 49 - 98 kPa (0.5 - 1.0 kgf/cm2)
High pressure side about 686 - 981 kPa (7.0 - 10 kgf/
cm2)
Gas bubbles are continuously observed through the sight
glass
The temperature of the air blown out does not decrease
Possible cause
Insufficient refrigerant level due to the refrigerant leakage
Correction
Inspect and repair the refrigerant leakage section
Fill the refrigerant up to the specified level
Symptom
Insufficient cooling
Both the high- and low-pressure values are high
The low pressure side is at about 245 - 294 kPa (2.5 - 3.0
kgf/cm2)
The high pressure side is at about 2256 - 2452 kPa (23 -
25 kgf/cm2)
No gas bubbles are observed through the sight glass even
after lowering the engine rpm
The temperature of the air blown out does not decrease
Possible cause
Over-filled refrigerant
Insufficient cooling of the condenser
Correction
Inspect the refrigerant level and fill it up to the specified
level
Clean the condenser
Inspect and repair the condenser fan
Symptom
Insufficient cooling
Both the high- and low-pressure values are high
The low pressure side is at about 245 - 294 kPa (2.5 - 3.0
kgf/cm2)
21C-4 Functional Inspection (All models)
The high pressure side is at about 2256 - 2452 (23 - 25
kgf/cm2)
The pipe at the low pressure side is not cold
Gas bubbles passes through the sight glass
Possible cause
Air entry into the air conditioning cycle due to
insufficient vacuuming
Correction
Perform vacuuming thoroughly and fill the refrigerant up
to the specified level
Symptom
Insufficient cooling
Both the high- and low-pressure values are high
The low pressure side is at about 294 - 392 kPa (3.0 - 4.0
kgf/cm2)
The high pressure side is at about 1961 - 2452 kPa (20 -
25 kgf/cm2)
Frosting occurs at the low pressure side pipe
Possible cause
The expansion valve is malfunctioning
Correction
Inspect the mounting condition of the thermosensor, and
then if no abnormality is found, replace the expansion
valve
Symptom
Not cold
The pressure at the low pressure side is too high while the
pressure at the high pressure side is too low
The low pressure side is at about 392 - 588 kPa (4.0 - 6.0
kgf/cm2)
The high pressure side is at about 686 - 1079 kPa (7.0 -
11 kgf/cm2)
The high and low pressures balance immediately after
turning off the air conditioner
Possible cause
Malfunctioning during compression due to defective
compressor
Correction
Replace the compressor
Symptom
Cold only during some time
The pressure at the low pressure side becomes negative at
times, or the pressure at the high pressure side also drops,
but normal in other instances
Functions properly immediately after the air conditioner
starts operating, but the pressure at the low pressure side
indicates a negative pressure after a while
The pressure at the low pressure side is negative - approx.
127 kPa(1.3 kgf/cm2)
The high pressure side about 588 - 1765 kPa (6.0 - 18
kgf/cm2)
Possible cause
The moisture freezes at the expansion valve as moisture
entered the air conditioning cycle, thus blocking the cycle
at times, but melts and returns to normal at other times
Correction
Replace the expansion valve
Replace the receiver dryer and the compressor oil
Perform vacuuming thoroughly and fill the refrigerant up
to the specified level
Symptom
Cold only during some time
The pressure at the low pressure side becomes negative
and the pressure at the high pressure side is also low The
pressure at the low pressure side is negative
The high pressure side is at about 490 - 588 kPa (5.0 - 6.0
kgf/cm2)
Frosting occurs at the receiver dryer or the front and rear
piping joints of the expansion valve
There is a large temperature difference between the IN
and OUT sides of the defective section
Possible cause
The cycle is blocked due to freezing of moisture or
presence of foreign substances
The cycle is blocked due to defective thermosensor of the
expansion valve
If the cycle is completely clogged, a negative pressure
value appears immediately, whereas the pressure drops
gradually to a negative value if it is slightly clogged
Action
When moisture enters the cycle, replace the receiver
dryer and the compressor oil, and fill the refrigerant up to
the specified level Replace the expansion valve if the
thermosensor is defective
Functional Inspection (All models) 21C-5
Automatic air conditioning control unit power circuit inspection
1. Automatic air conditioning control unit power circuit
inspection description of function
Inspect the control unit circuit because if there is a
problem in the control unit power supply circuit and
ground circuit, trouble diagnosis cannot be accurately
performed.
2. Automatic air conditioning control unit power circuit
inspection inspection
Inspection when a malfunction of the power supply
circuit or GND circuit of the control unit is suspected
1. Inspect the fuse.
Meter fuse
2. If the fuse is open circuit, replace it.
Note
If the fuse continues to wire-melt, repair the
cause of open circuits.
3. Disconnect the harness connector from the control
panel assembly.
4. Start the engine.
5. Measure the voltage value between the harness
connector of the control panel assembly and GND.
Note
Measure the voltage value between terminal
No.23 and GND.
Voltage 12 V
6. When it is at or below the standard value, repair the
open circuits between the meter fuse and the control
panel assembly harness connector.
Note
Repair the circuit between the fuse and
terminal No.23.
7. When the temperature is at or above the standard
value, inspect continuity between the harness
connector of the control panel assembly and GND.
Note
Inspect between terminal No. 38 and the GND.
8. When there is no continuity, repair the open circuit
in the circuit between the harness connector of the
control panel assembly and the GND.
Note
Repair the circuit between terminal No. 38 and
the GND.
9. Turn OFF the ignition switch.
10. Measure the voltage value between the harness
connector of the control panel assembly and GND.
Note
Measure the voltage value between terminal
No. 3 and the GND.
Voltage 12 V
11. When it is at or below the standard value, repair the
open circuits between the meter fuse and the control
panel assembly harness connector.
Note
Repair the circuit between the fuse and
terminal No.3.
21C-6 Functional Inspection (All models)
Description HVAC
Symptom
(All models)
Table of Contents
Outlet selector switch moves but the mode door does not
operate...........................................................................21D-2
Mode door cannot be set to a specified mode...............21D-3
Intake actuator does not work.......................................21D-4
Magnetic clutch is not functioning................................21D-5
Magnetic clutch is not functioning (automatic air
conditioning).................................................................21D-6
Blower motor does not run (automatic air conditioning)
.......................................................................................21D-7
Blower motor does not stop operating..........................21D-8
Cooling system is not functioning or is weak...............21D-9
Insufficient air flow from the cooling system.............21D-10
Blower motor does not operate regardless of the switch
position........................................................................21D-11
Blower motor does not function at the "LOW" position
.....................................................................................21D-12
Blower motor does not function at the "MEDIUM LOW"
.....................................................................................21D-13
Blower motor does not function at the "MEDIUM HI"
.....................................................................................21D-14
Blower motor does not function at the "HI" position..21D-15
Code 22 shows on the control panel display...............21D-16
Code 24 shows on the control panel display...............21D-17
Code 25 shows on the control panel display...............21D-18
Code 31 shows on the control panel display...............21D-19
Code 32 shows on the control panel display...............21D-20
Code 33 shows on the control panel display...............21D-21
Code 34 shows on the control panel display...............21D-22
Code 35 shows on the control panel display...............21D-23
Code 37 shows on the control panel display...............21D-24
Code 38 shows on the control panel display...............21D-25
Code 39 shows on the control panel display...............21D-26
Symptom (All models) 21D-1
Outlet selector switch moves but the mode door does not operate
1. Outlet selector switch moves but the mode door does
not operate diagnostics
The cable attachment lock clamp is defective or detached
Correct the lock clamp.
The link unit of the heater unit or the blower assembly is
defective
Repair the link unit.
21D-2 Symptom (All models)
Mode door cannot be set to a specified mode
1. Mode door cannot be set to a specified mode
diagnostics
The link unit of the heater unit or the blower assembly is
defective
Repair the link unit.
The control cable requires proper adjustment
Adjust the control cable.
Symptom (All models) 21D-3
Intake actuator does not work
1. Intake actuator does not work diagnostics
Each terminal No. indicates the connector terminal at the
body harness side.
1. Start the engine.
2. Disconnect the harness connector from the intake
actuator.
3. Measure a voltage using a DMM.
Note
Measure the voltage between the intake
actuator terminal 1 and GND. If any
abnormality is found, repair the harness
between the intake actuator terminal 1 and
Electrical IG1 FUSE.
Voltage 12 V
4. Inspect the intake actuator.
Note
Replace it if any abnormality is found.
5. Inspect continuity using a DMM.
Note
Inspect between intake actuator terminal 1 and
control unit terminal 6. Repair the parts if any
abnormality is found.
6. Inspect continuity using a DMM.
Note
Inspect between the intake actuator terminal 3
and the control unit terminal 7. Repair the
parts if any abnormality is found.
7. Replace the control panel assembly with a new one.
21D-4 Symptom (All models)
Magnetic clutch is not functioning
1. Magnetic clutch is not functioning diagnostics
Confirm that the fan switch system is functioning
properly before performing the following inspection.
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the air conditioner fuse.
If any abnormality is found in the fuse, inspect and repair
the cause of melting first, and then replace the fuse and
other parts.
Inspect the air conditioner compressor relay.
Check by conducting a continuity test. Replace the relay
if any abnormality is found.
Inspect the pressure switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Check the air conditioner switch.
Check by conducting a continuity test. Replace the switch
if any abnormality is found.
Inspect the ECM.
Check the DTC and replace the ECM if any abnormality
is found.
Inspect the electronic thermostat.
If the electronic thermostat is defective, replace it.
Inspect the magnetic clutch.
If any abnormality is found in the magnetic clutch,
replace it.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between the blower motor relay terminal 2 and the air
conditioner compressor relay terminal 1
Between the Fuse (ElectricalIG2) and the air conditioner
compressor relay terminal 3
Between the Fuse (ElectricalIG2) and the ECM terminal
34
Between the air conditioner compressor relay terminal 3
and the air conditioner compressor relay terminal 4
Between the air conditioner compressor relay terminal 4
and the ECM terminal 12
Between the air conditioner compressor relay terminal 2
and the magnetic clutch
Between the blower motor relay terminal 2 and the
pressure switch terminal 2
Between the pressure switch terminal 1 and the electronic
thermostat terminal 2
Between the electronic thermostat terminal 1and the
GND
Between the Control Lever terminal 9 and the GND
Each terminal No. indicates the connector terminal at
the chassis harness side.
Symptom (All models) 21D-5
Magnetic clutch is not functioning (automatic air conditioning)
1. Magnetic clutch is not functioning (automatic air
conditioning) diagnostics
Confirm that the blower motor is functioning properly
before performing the following inspection. It is assumed
that the blower motor system circuits are normal.
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the air conditioner fuse.
If any abnormality is found in the fuse, inspect and repair
the cause of melting first, and then replace the fuse and
other parts.
Inspect the air conditioner compressor relay.
Check by conducting a continuity test. Replace the relay
if any abnormality is found.
Inspect the pressure switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Inspect the ECM.
Check the DTC and replace the ECM if any abnormality
is found.
Inspect the magnetic clutch.
If any abnormality is found in the magnetic clutch,
replace it.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between the blower motor relay terminal 2 and the air
conditioner compressor relay terminal 1
Between the Fuse (ElectricalIG2) and the pressure
switch terminal 2
Between the pressure switch terminal 1 and the ECM
terminal 34
Between the air conditioner compressor relay terminal 3
and the air conditioner compressor relay terminal 4
Between the air conditioner compressor relay terminal 4
and the ECM terminal 12
Between the air conditioner compressor relay terminal 2
and the magnetic clutch
Between the Control Panel terminal 1 and the ECM
terminal 58 (CAN)
Between the Control Panel terminal 21 and the ECM
terminal 78 (CAN)
Between the Control Panel terminal 38 and the GND
Each terminal No. indicates the connector terminal at
the chassis harness side.
If no problems are found in the components and circuits
in the inspections, and the control unit power supply
circuits do not have a problem, replace the control unit
assembly.
21D-6 Symptom (All models)
Blower motor does not run (automatic air conditioning)
1. Blower motor does not run (automatic air
conditioning) diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the blower motor fuse.
If any abnormality is found in the fuse, inspect and repair
the cause of the wire-melting first, and then replace the
fuse.
Inspect the blower motor relay.
Replace the relay if an abnormality is found.
Inspect the blower motor.
Replace the relay if an abnormality is found.
Inspect the ECM.
Check the DTC and replace the ECM if any abnormality
is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between the blower motor relay terminal 1 and the
blower motor terminal 1.
Between the blower motor terminal 2 and the blower
module terminal 2.
Between the blower module terminal 1 and the control
panel terminal 19.
Between the blower module terminal 3 and the control
panel terminal 20.
Each terminal No. indicates the connector terminal at
the chassis harness side.
If no problems are found in the components and circuits
in the inspections, and the control panel power supply
circuits do not have a problem, replace the blower
module or the control panel assembly.
Symptom (All models) 21D-7
Blower motor does not stop operating
1. Blower motor does not stop operating diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the fan switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between the control lever terminal (8 pin type) 4 or 3 and
the control lever terminal (8 pin type) 7 or 8. Short
circuit in the wire(s)(manual type)
If no problems are found in the components and circuits
in the inspections, and the control lever power supply
circuits do not have a problem, replace the control lever
assembly.
Between the blower module terminal 2 and 4 Short
circuit in the wire(s)(automatic type)
Each terminal No. indicates the connector terminal at
the chassis harness side.
If no problems are found in the components and circuits
in the inspections, and the control panel assembly power
supply circuits do not have a problem, replace the control
panel assembly.
If no problems are found in the components and circuits
in the inspections, and the control panel power supply
circuit does not have a problem, replace the control panel
assembly.
21D-8 Symptom (All models)
Cooling system is not functioning or is weak
1. Cooling system is not functioning or is weak
diagnostics
The magnetic clutch is not functioning
Inspect the magnetic clutch system.
Compressor does not rotate properly.
Adjust the drive belt to the specified tension or replace it
with a new one.
Clean the surface of the magnetic clutch or replace it with
a new one.
Adjust the clearance between the magnetic clutch and the
drive plate.
If the compressor oil is leaking from the shaft seal or the
shell, replace the compressor.
If the compressor is burnt out, replace the compressor.
Insufficient or excessive refrigerant
Inspect the refrigerant level.
Refrigerant leakage from the air conditioning system
Check for leaks in the air conditioner system and the
refrigerant line.
Retighten or repair it.
Insufficient heat dissipation from the condenser
Clean the condenser, inspect operations of the radiator
fan and not have condenser fan.
Temperature control link unit of the heater unit is
defective
Repair the link unit.
Expansion valve is not functioning properly
Replace the expansion valve.
The electronic thermostat is not functioning properly
Inspect the electronic thermostat and replace it if any
abnormality is found.
Symptom (All models) 21D-9
Insufficient air flow from the cooling system
1. Insufficient air flow from the cooling system
diagnostics
Clogging of or damage to the evaporator
Inspect the evaporator core, and clean or replace the core.
Air leakage from the cooling unit or the duct
Inspect the connection of the evaporator and the duct, and
repair if any abnormality is found.
The blower motor does not rotate properly
Inspect the fan switch system.
21D-10 Symptom (All models)
Blower motor does not operate regardless of the switch position
1. Blower motor does not operate regardless of the switch
position diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect or repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection is not properly made or is very
dirty, repair and clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness has not come
loose, causing a short circuit with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the blower motor fuse.
If any abnormality is found in the fuse such as wire
melting, inspect or repair the cause of the melting first,
and then replace the fuse.
Inspect the blower motor relay.
Check by conducting a continuity test. Replace the relay
if any abnormality is found.
Inspect the blower resistor.
Check by conducting a continuity test. Replace the
blower resistor if any abnormality is found.
Inspect the fan switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Inspect the blower motor.
Replace the blower motor if an abnormality is found.
Inspect the ECM.
Check the DTC and replace the ECM if any abnormality
is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between the blower motor relay terminal 1 and the
blower motor terminal 1.
Between the blower motor terminal 2 and the blower
resistor terminal 3.
Between the blower resistor terminal 3 and the control
lever terminal (8pin type) 2 or 5 or 6.
Between the control lever terminal (8pin type) 7 or 8 and
the GND.
If no problems are found in the components and circuits
in the inspections, and the control lever power supply
circuits do not have a problem, replace the control lever
assembly.
If no problems are found in the components and circuits
in the inspections, and the control lever power supply
circuit does not have a problem, replace the control lever
assembly.
Symptom (All models) 21D-11
Blower motor does not function at the "LOW" position
1. Blower motor does not function at the "LOW"
position diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the blower resistor.
Check by conducting a continuity test. Replace the
blower resistor if any abnormality is found.
Inspect the fan switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between blower resistor terminal 2 and control lever
terminal (8pin type) 5.
Each terminal No. indicates the connector terminal at
the chassis harness side.
21D-12 Symptom (All models)
Blower motor does not function at the "MEDIUM LOW"
1. Blower motor does not function at the "MEDIUM
LOW" diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the blower resistor.
Check by conducting a continuity test. Replace the
blower resistor if any abnormality is found.
Inspect the fan switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between blower resistor terminal 4 and control lever
terminal (8pin type) 5.Each terminal No. indicates the
connector terminal at the chassis harness side.
Symptom (All models) 21D-13
Blower motor does not function at the "MEDIUM HI"
1. Blower motor does not function at the "MEDIUM HI"
diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the blower resistor.
Check by conducting a continuity test. Replace the
blower resistor if any abnormality is found.
Inspect the fan switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between blower resistor terminal 1 and control lever
terminal (8pin type) 6.Each terminal No. indicates the
connector terminal at the chassis harness side.
21D-14 Symptom (All models)
Blower motor does not function at the "HI" position
1. Blower motor does not function at the "HI" position
diagnostics
Note
Prior confirmation and visual inspection
Check that the battery voltage is normal.
If the battery voltage is not normal, charge or replace the
battery.
Check that the fuses are in normal condition.
If any abnormality is found in a fuse such as wire
melting, inspect and repair the cause of the melting first,
and then replace the fuse.
Check that the ground connection is normal.
If the ground connection has an abnormality, repair and
clean.
Check that the harnesses and connectors are normal.
Check the connector for connection failures and the
harness for abnormalities such as abrasion or bends, etc.
Check that the wire inside the harness is not short
circuited with other circuits.
Check the effect of the post-installed electrical
accessories such as wireless devices and lights, etc.
Turn OFF or remove the post-mounted electrical
components, so that they do not affect the inspection or
the operation.
Note
Inspection of the structural components
Inspect the blower resistor.
Check by conducting a continuity test. Replace the
blower resistor if any abnormality is found.
Inspect the fan switch.
Check by conducting a continuity test. Replace the fan
switch if any abnormality is found.
Note
Inspection of the circuit
Check the following circuits for abnormalities. Repair or
replace if any abnormality is found.
Between blower motor terminal 2 and control lever
terminal (8Pin type) 3 or 4
Each terminal No. indicates the connector terminal at
the chassis harness side.
Symptom (All models) 21D-15
Code 22 shows on the control panel display
1. Code 22 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Disconnect the harness connector from the inside air
temperature sensor.
3. Inspect the inside air temperature sensor.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Inside air temperature
sensor inspection".
4. If a problem is found, replace the inside air
temperature sensor.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Inside air temperature
sensor removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Inside air temperature
sensor installation".
5. Inspect the circuit between the control panel
assembly and the inside air temperature sensor.
Note
There should be no open circuit or high
resistance.
There should be no short circuit between
circuits.
There should be no short circuit with a metal
component such as a body.
6. If a problem is found, repair the circuit.
7. When the circuit is normal, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
8. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
9. Restore the vehicle.
10. Turn the ignition switch off for 30 seconds or longer.
11. Turn ON the ignition switch.
12. Perform a self-diagnosis, and confirm that the
normal code is displayed.
21D-16 Symptom (All models)
Code 24 shows on the control panel display
1. Code 24 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Disconnect the harness connector from the fin
sensor.
3. Measure the resistance value of the fin sensor.
Standard 8 k At 0 C (32 F)
4. If a problem is found, replace the fin sensor.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Fin sensor removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Fin sensor installation".
5. Inspect the circuit between the control panel
assembly and the fin sensor.
Note
There should be no open circuit or high
resistance.
There should be no short circuit between
circuits.
There should be no short circuit with a metal
component such as a body.
6. If a problem is found, repair the circuit.
7. When the circuit is normal, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
8. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
9. Restore the vehicle.
10. Turn the ignition switch off for 30 seconds or longer.
11. Turn ON the ignition switch.
12. Perform a self-diagnosis, and confirm that the
normal code is displayed.
Symptom (All models) 21D-17
Code 25 shows on the control panel display
1. Code 25 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Disconnect the harness connector from the sun
sensor.
3. Inspect the sun sensor.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Sun sensor inspection".
4. If a problem is found, replace the sun sensor.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Sun sensor removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Sun sensor installation".
5. Inspect the circuit between the control panel
assembly and the sun sensor.
Note
There should be no open circuit or high
resistance.
There should be no short circuit between
circuits.
There should be no short circuit with a metal
component such as a body.
6. If a problem is found, repair the circuit.
7. When the circuit is normal, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
8. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
9. Restore the vehicle.
10. Turn the ignition switch off for 30 seconds or longer.
11. Turn ON the ignition switch.
12. Perform a self-diagnosis, and confirm that the
normal code is displayed.
21D-18 Symptom (All models)
Code 31 shows on the control panel display
1. Code 31 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the mode actuator
and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the mode
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
mode actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the outlet selector switch and set to the
VENT position.
18. Perform a self-diagnosis.
19. When code 31 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the outlet selector switch and set to the
VENT position.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
Symptom (All models) 21D-19
Code 32 shows on the control panel display
1. Code 32 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the mode actuator
and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the mode
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
mode actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the outlet selector switch and set to the B/L
position.
18. Perform a self-diagnosis.
19. When code 32 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the outlet selector switch and set to the B/L
position.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
21D-20 Symptom (All models)
Code 33 shows on the control panel display
1. Code 33 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the mode actuator
and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the mode
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
mode actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the outlet selector switch and set to the
FOOT position.
18. Perform a self-diagnosis.
19. When code 33 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode
actuator installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the outlet selector switch and set to the
FOOT position.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
Symptom (All models) 21D-21
Code 34 shows on the control panel display
1. Code 34 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the mode actuator
and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the mode
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
mode actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the outlet selector switch and set to the DEF/
FOOT position.
18. Perform a self-diagnosis.
19. When code 34 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the outlet selector switch and set to the DEF/
FOOT position.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
21D-22 Symptom (All models)
Code 35 shows on the control panel display
1. Code 35 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the mode actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the mode actuator
and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the mode
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
mode actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Mode
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the outlet selector switch and set to the DEF
position.
18. Perform a self-diagnosis.
19. When code 35 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the outlet selector switch and set to the DEF
position.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
Symptom (All models) 21D-23
Code 37 shows on the control panel display
1. Code 37 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the intake actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the intake actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the intake
actuator and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the intake
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
intake actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Intake actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Intake
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the outside air intake switch.
18. Perform a self-diagnosis.
19. When code 37 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the outside air intake switch.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
21D-24 Symptom (All models)
Code 38 shows on the control panel display
1. Code 38 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the intake actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the intake actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the intake
actuator and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the intake
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
intake actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Intake actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Intake
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Perform step 4 of the self-diagnosis function.
18. Perform a self-diagnosis.
19. When code 38 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Perform step 4 of the self-diagnosis function.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
Symptom (All models) 21D-25
Code 39 shows on the control panel display
1. Code 39 shows on the control panel display
diagnostics
1. Turn OFF the ignition switch.
2. Inspect the power supply circuit between the control
panel assembly and the intake actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the signal
circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
3. If a problem is found, repair the power supply
circuit.
4. Inspect the signal circuit between the control panel
assembly and the intake actuator.
Note
There should be no open circuit or high
resistance.
There should be no short circuit to the battery
or ignition power supply circuit.
There should be no short circuit in the power
supply circuit.
There should be no short circuit in the ground
circuit.
There should be no short circuit with a metal
component such as a body.
5. If a problem is found, repair the signal circuit.
6. Inspect the ground circuit between the intake
actuator and the ground terminal.
Note
There should be no open circuit or high
resistance.
7. If a problem is found, repair the ground circuit.
8. When the circuit is normal, inspect the intake
actuator harness connector for a contact failure.
9. If a problem is found, repair the harness connector.
10. Inspect the control panel assembly harness connector
for a contact failure.
11. If a problem is found, repair the harness connector.
12. When the harness connector is normal, replace the
intake actuator.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Intake actuator removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Intake
actuator installation".
13. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
14. Restore the vehicle.
15. Turn the ignition switch off for 30 seconds or longer.
16. Turn ON the ignition switch.
17. Operate the inside air recirculation switch.
18. Perform a self-diagnosis.
19. When code 39 is detected, replace the control panel
assembly.
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly removal".
Refer to "7.HVAC 7B.Heater, Ventilator,
Airconditioner(All models) Control panel
assembly installation".
20. Clear the self-diagnosis code.
Note
Remove the METER (+B) 10A fuse and the
ELEC IG1 10A fuse.
21. Restore the vehicle.
22. Turn the ignition switch off for 30 seconds or longer.
23. Turn ON the ignition switch.
24. Operate the inside air recirculation switch.
25. Perform a self-diagnosis, and confirm that the
normal code is displayed.
21D-26 Symptom (All models)
HVAC
Heater, Ventilator, Airconditioner
(All models)
Table of Contents
Sun sensor........................................................................7B-3
removal.......................................................................7B-3
inspection....................................................................7B-4
installation...................................................................7B-5
Inside air temperature sensor...........................................7B-6
removal.......................................................................7B-6
inspection....................................................................7B-7
installation...................................................................7B-8
Heater evaporator unit assembly.....................................7B-9
removal.......................................................................7B-9
installation.................................................................7B-18
A/C compressor assembly.............................................7B-26
removal.....................................................................7B-26
installation.................................................................7B-27
Blower motor assembly.................................................7B-29
removal.....................................................................7B-29
inspection..................................................................7B-30
installation.................................................................7B-31
Intake actuator...............................................................7B-32
removal.....................................................................7B-32
inspection..................................................................7B-33
installation.................................................................7B-34
A/C compressor relay....................................................7B-35
removal.....................................................................7B-35
inspection..................................................................7B-36
installation.................................................................7B-37
Ventilation duct.............................................................7B-38
removal.....................................................................7B-38
installation.................................................................7B-48
Evaporator core.............................................................7B-56
removal.....................................................................7B-56
installation.................................................................7B-65
Blower assembly...........................................................7B-73
removal.....................................................................7B-73
installation.................................................................7B-82
Blower module assembly..............................................7B-88
removal.....................................................................7B-88
inspection..................................................................7B-89
installation.................................................................7B-90
Blower resistor..............................................................7B-91
removal.....................................................................7B-91
inspection..................................................................7B-92
installation.................................................................7B-93
Pressure switch..............................................................7B-94
removal.....................................................................7B-94
inspection..................................................................7B-95
installation.................................................................7B-96
Mode actuator................................................................7B-97
removal.....................................................................7B-97
inspection..................................................................7B-98
installation.................................................................7B-99
Control lever assembly................................................7B-100
removal...................................................................7B-100
inspection................................................................7B-101
installation...............................................................7B-102
Control panel assembly...............................................7B-104
removal...................................................................7B-104
installation...............................................................7B-105
Outside air temperature sensor....................................7B-106
removal...................................................................7B-106
inspection................................................................7B-107
installation...............................................................7B-108
Condenser assembly....................................................7B-109
removal...................................................................7B-109
installation...............................................................7B-112
Center ventilation grille...............................................7B-115
removal...................................................................7B-115
installation...............................................................7B-116
Center vent grille with manual air conditioning..........7B-117
removal...................................................................7B-117
installation...............................................................7B-118
Blower motor relay......................................................7B-119
removal...................................................................7B-119
inspection................................................................7B-120
installation...............................................................7B-121
Case assembly.............................................................7B-122
removal...................................................................7B-122
installation...............................................................7B-131
Fin sensor....................................................................7B-138
removal...................................................................7B-138
installation...............................................................7B-147
Electronic thermostat...................................................7B-155
Heater, Ventilator, Airconditioner (All models) 7B-1
removal...................................................................7B-155
inspection................................................................7B-164
installation...............................................................7B-165
Defroster nozzle..........................................................7B-173
removal...................................................................7B-173
installation...............................................................7B-183
Supplementary Information.........................................7B-191
7B-2 Heater, Ventilator, Airconditioner (All models)
Sun sensor
removal
1. Sun sensor removal
1. Remove the sun sensor from the instrument panel.
2. Disconnect the harness connector from the sun
sensor.
Note
Remove it together with the instrument panel
upper cover from the instrument panel.
Remove the sun sensor from instrument panel
upper cover.
Heater, Ventilator, Airconditioner (All models) 7B-3
inspection
1. Sun sensor inspection
1. Inspect the sun sensor.
Note
Remove the sun sensor.
Using a circuit tester, connect the tester
positive terminal to the connector terminal 2
and the tester negative terminal to the
connector terminal 1.
Cover the sensor with a cloth to protect it from
direct light irradiation, and measure the
resistance between the connector terminals.
Resistance No continuity
Note
Using a circuit tester, connect the tester
positive terminal to the connector terminal 2
and the tester negative terminal to the
connector terminal 1.
Measure the resistance between the connector
terminals when the light from an inspection
light is projected within 300 mm {11.8 in} of the
sensor.
Resistance A value other than
Caution
As the sensor may not respond to a weak light,
use an incandescent light for the inspection
light, and make a measurement with the light
positioned within 300 mm {11.8 in} of the
sensor.
7B-4 Heater, Ventilator, Airconditioner (All models)
installation
1. Sun sensor installation
Note
Install the sun sensor to the instrument panel
upper cover.
1. Connect the harness connector to the sun sensor.
2. Install the sun sensor to the instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-5
Inside air temperature sensor
removal
1. Hood lock control lever removal
1. Remove the hood lock control lever from the
instrument panel.
Note
Remove the 2 screws.
2. Instrument panel driver-side lower cover removal
1. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
2. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
2. DLC
3. Inside air temperature sensor removal
1. Remove the inside air temperature sensor from the
instrument panel assist-side lower cover.
2. Disconnect the harness connector from the inside air
temperature sensor.
Note
Remove the 1 screw.
Disconnect the aspirator hose.
1. Inside air temperature sensor
2. Screw
7B-6 Heater, Ventilator, Airconditioner (All models)
inspection
1. Inside air temperature sensor inspection
1. Inspect the aspirator.
Note
Operate the blower fan motor.
Confirm that smoke is drawn in when it is
brought near the inside air temperature sensor
inlet.
When it is not drawn in, inspect for aspirator
hose disconnection, or inspect the aspirator
unit itself.
1. Inside air temperature sensor inlet
2. Inspect the inside air temperature sensor.
Note
Remove the inside air temperature sensor,
and measure the continuity and the resistance
value between the terminals No. 1 and No. 2
of the inside air temperature sensor side
connector.
Confirm that the resistance value gets smaller
as the ambient temperature at the temperature
sensing section of the sensor increases, and
the value gets larger as that temperature
decreases.
Terminal
No.
Continuity
Resistance
value
Conditions
1-2
Continuity
exists
2.1 to 2.3 k
25
{ 77 F }
Heater, Ventilator, Airconditioner (All models) 7B-7
installation
1. Inside air temperature sensor installation
1. Install the inside air temperature sensor to the
instrument panel assist-side lower cover.
2. Connect the harness connector to the inside air
temperature sensor.
Note
Install the 1 screw.
Connect the aspirator hose.
2. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Hood lock control lever installation
1. Connect the hood lock control lever to the control
cable.
2. Install the hood lock control lever to the instrument
panel driver-side lower cover.
1. Hood lock control lever
2. Control cable
3. Screw
Note
Confirm that the engine hood lock assembly
and hood lock control lever operate normally.
7B-8 Heater, Ventilator, Airconditioner (All models)
Heater evaporator unit assembly
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
3. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below is for the tray type, excluding the front
bench seat.
Open the cover and remove the 2 screws.
Pull up the console tray and remove the 2 clips
at the front.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
Below is for 4WD except for the center console
type.
Disconnect the connector of the 4WD switch.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
4. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
5. Glove box removal
1. Remove the glove box from the instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-9
1. Glove box
2. Instrument panel assist side lower cover
6. Side cover removal
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
7. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
8. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
7B-10 Heater, Ventilator, Airconditioner (All models)
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
2. DLC
9. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag, wear gloves and
safety glasses.
After handling, wash your hands with soap.
Note
Handling of an undeployed airbag assembly
Warning
When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
When carrying the airbag, never hang the
connector or harness on your hand.
When putting down an undeployed airbag,
make sure to face the trim cover upward.
Do not place any other item on the steering
wheel with the airbag surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
If the SRS coil assembly is damaged, replace
it.
10. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
Heater, Ventilator, Airconditioner (All models) 7B-11
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
11. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
7B-12 Heater, Ventilator, Airconditioner (All models)
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
12. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
13. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
14. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
15. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
Heater, Ventilator, Airconditioner (All models) 7B-13
16. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
17. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
18. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
19. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
7B-14 Heater, Ventilator, Airconditioner (All models)
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
20. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
21. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
22. Sun sensor removal
Note
The following applies to auto A/C.
Heater, Ventilator, Airconditioner (All models) 7B-15
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
23. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
24. Blower assembly removal
1. Remove the blower assembly from vehicle.
Note
Remove the 2 screws and 1 nut.
7B-16 Heater, Ventilator, Airconditioner (All models)
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
25. A/C pipe disconnect
1. Disconnect the A/C pipe from the heater evaporator
unit assembly.
Note
Remove the fitting of A/C pipe.
Remove 1 of the A/C pipe connecting bolts.
After disconnecting each pipe, put a cap or a
cover on the connection to prevent the foreign
matter from getting into the A/C pipe.
26. Heater evaporator unit assembly removal
1. Remove the heater evaporator unit assembly from
vehicle.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
Note
After disconnecting each pipe, put a cap or a
cover on the connection to prevent the foreign
matter from getting into the A/C cycle.
Heater, Ventilator, Airconditioner (All models) 7B-17
installation
1. Heater evaporator unit assembly installation
1. Install the heater evaporator unit assembly to vehicle.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
2. A/C pipe connect
1. Connect the A/C pipe to the heater evaporator unit
assembly.
Note
Do not reuse the O-ring of A/C pipe. Be sure to
replace with a new one.
Apply compressor oil on the O-ring.
Tighten the A/C pipe connection at the
specified torque.
Tightening torque 6.6 Nm { 0.7 kgfm / 58 lbin }
3. Blower assembly installation
1. Install the blower assembly to vehicle.
Note
Tighten the 2 screws and 1 nut.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
4. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
7B-18 Heater, Ventilator, Airconditioner (All models)
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
5. Control cable connect
1. Adjust the control cable.
Note
Adjust the air source control cable.
Set the air source select lever to the "FRESH"
position on the left side.
Heater, Ventilator, Airconditioner (All models) 7B-19
2. Install the control cable to the blower assembly.
Note
Make sure that the control cable is firmly
fastened to the original position at the lock
clamp.
After installation, inspect the operation of the
control lever assembly.
Below is for auto A/C specification.
Connect the intake actuator connector.
6. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
7. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
8. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
9. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
7B-20 Heater, Ventilator, Airconditioner (All models)
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
10. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
Heater, Ventilator, Airconditioner (All models) 7B-21
11. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
12. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
13. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
14. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
15. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
16. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
7B-22 Heater, Ventilator, Airconditioner (All models)
1. Steering cowl upper
2. Steering cowl lower
17. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
18. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
19. Battery ground cable installation
1. Install the battery ground cable to the battery.
20. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
21. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the 4 screws.
Heater, Ventilator, Airconditioner (All models) 7B-23
1. Glove box
2. Instrument panel assist side lower cover
22. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
23. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
24. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
Note
Install the 2 fixing screws.
7B-24 Heater, Ventilator, Airconditioner (All models)
1. Hood lock control lever
2. Control cable
3. Screw
25. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
26. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
27. Refrigerant preparation
1. Fill refrigerant.
Caution
For refilling of refrigerant, refer to the
instruction manual for the refrigerant collector.
Heater, Ventilator, Airconditioner (All models) 7B-25
A/C compressor assembly
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Intake hose removal
1. Remove the intake hose from the intercooler.
Note
Remove 1 of the band clips.
1. Intake hose
2. Compressor
3. A/C compressor drive belt
3. A/C compressor drive belt removal
1. Remove the A/C compressor drive belt from the A/C
compressor assembly.
Note
Loosen the tension pulley lock nut.
Loosen the tension pulley adjust bolt to
remove the belt.
Remove the magnetic clutch harness
connector.
4. A/C pipe removal
1. Remove the A/C pipe from the A/C compressor
assembly.
Note
Remove the A/C pipe mounting bolt.
After disconnecting the A/C pipe, put a cap or
a cover on the connection to prevent foreign
object from getting into the A/C pipe.
5. A/C compressor assembly removal
1. Remove the A/C compressor assembly from the A/C
compressor bracket.
Note
Remove the 4 mounting bolts.
7B-26 Heater, Ventilator, Airconditioner (All models)
installation
1. A/C compressor assembly installation
1. Install the A/C compressor assembly to the bracket.
Tightening torque 51 Nm { 5.2 kgfm / 38 lbft }
2. Connect the harness connector to the A/C
compressor assembly.
1. Air intake hose
2. Compressor
3. Air conditioner compressor drive belt
2. A/C pipe installation
1. Install the A/C pipe to the heater evaporator unit
assembly.
Note
Do not reuse the O-ring.
Always replace them with new ones.
Make sure to apply compressor oil to the
replaced O-ring before connecting the hose.
Tighten the A/C pipe mounting bolt at the
specified torque.
Tightening torque 15 Nm { 1.5 kgfm / 11 lbft }
3. A/C compressor drive belt installation
1. Install the A/C compressor drive belt to the A/C
compressor assembly.
4. A/C compressor drive belt adjustment
1. Adjust tension to a standard value using a tension
meter.
Note
Loosen the lock nut and adjust bolt of the A/C
compressor drive belt tension pulley to free the
belt.
Turn the tension pulley adjust bolt to adjust the
belt.
Press the specified position on the belt with
the specified load to inspect the amount of belt
flex.
Load 98 N { 10 kg / 22 lb }
1. A/C compressor drive belt measuring section
Note
A method for confirming if the precise tension
has been set is to use a sonic tension meter.
A/C compressor drive belt
For flex amount
For use of sonic
tension meter
Amount of flex
Frequency of
vibrations
For a new
product
12.4 to 16.4 mm
0.488 - 0.646 in
92 to 112 Hz
When
adjusting
the tension
16.5 to 19.1 mm
0.650 - 0.752 in
80 to 92 Hz
Note
After adjusting, tighten the tension pulley lock
nut at the specified torque.
Tightening torque 41 Nm { 4.2 kgfm / 30 lbft }
5. Intake hose installation
1. Install the intake hose to the intercooler.
Caution
Use a new clip.
Tightening torque 6 Nm { 0.7 kgfm / 57 lbin }
6. Refrigerant preparation
Heater, Ventilator, Airconditioner (All models) 7B-27
1. Fill refrigerant.
Caution
For refilling of refrigerant, refer to the
instruction manual for the refrigerant collector.
7B-28 Heater, Ventilator, Airconditioner (All models)
Blower motor assembly
removal
1. Glove box removal
1. Remove the glove box from the instrument panel.
Note
Remove the tabs of the hinge section.
2. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws, 4 clips and 2 tabs.
Remove the illumination light.
3. Blower motor assembly removal
1. Remove the blower motor assembly from the blower
assembly.
Note
Disconnect the connector of the blower motor
assembly.
Remove the 3 mounting screws of the blower
motor assembly.
1. Blower assembly
2. Instrument panel assist side lower cover
3. Glove box
4. Blower motor assembly
Heater, Ventilator, Airconditioner (All models) 7B-29
inspection
1. Blower motor assembly inspection
1. Inspect the blower motor assembly using tester.
Note
Connect the battery voltage positive side to the
terminal No. 2 and the negative side to the
terminal No. 1 of the blower motor.
Inspect whether the blower motor is normal.
7B-30 Heater, Ventilator, Airconditioner (All models)
installation
1. Blower motor assembly installation
1. Install the blower motor assembly to the blower
assembly.
Note
Install the 3 mounting screws of the blower
motor assembly.
Connect the blower motor assembly
connector.
1. Blower assembly
2. Instrument panel assist side lower cover
3. Glove box
4. Blower motor assembly
2. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the illumination light.
Install the 4 screws, 4 clips and 2 tabs.
3. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
Heater, Ventilator, Airconditioner (All models) 7B-31
Intake actuator
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Glove box removal
1. Remove the glove box from the instrument panel.
Note
Remove the tabs of the hinge section.
3. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws, 4 clips and 2 tabs.
Remove the illumination light.
4. Intake actuator removal
1. Remove the intake actuator from the blower
assembly.
Note
Disconnect 1 of the harness connector
connections.
Remove the 2 bolts.
1. Intake actuator
2. Blower assembly
7B-32 Heater, Ventilator, Airconditioner (All models)
inspection
1. Intake actuator inspection
1. Inspect the intake actuator.
Note
Turn ON the ignition switch.
Use a digital multimeter or oscilloscope to
check the signal voltage between intake
actuator connector terminals No. 1 and No. 2.
Use an oscilloscope to check the signal
waveform output between intake actuator
terminals No. 3 and No. 2.
Operate the A/C control switch and inspect
whether the motor rotates.
Instrument set 2V/DIV, 100ms/DIV
Measurement condition Fan switch LO
Note
Waveform
Note
Signal (pulse waveform)
Heater, Ventilator, Airconditioner (All models) 7B-33
installation
1. Intake actuator installation
1. Install the intake actuator to the blower assembly.
Note
Connect the rod.
Install the 2 intake actuator mounting bolts.
Connect harness connector to the intake
actuator.
1. Intake actuator
2. Blower assembly
2. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the illumination light.
Install the 4 screws, 4 clips and 2 tabs.
3. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
4. Battery ground cable connect
1. Connect the battery ground cable to the battery.
7B-34 Heater, Ventilator, Airconditioner (All models)
A/C compressor relay
removal
1. A/C compressor relay removal
Note
Fuse relay box
1. Remove the A/C compressor relay from the fuse
relay box.
1. A/C compressor relay
2. Blower motor relay
3. A/C fuse
Heater, Ventilator, Airconditioner (All models) 7B-35
inspection
1. A/C compressor relay inspection
1. Inspect the A/C compressor relay using tester.
Note
Inspect the continuity between the terminals at
the A/C compressor relay side.
Continuity inspection
When voltage is not
applied to terminals 3 -
5
Terminals 1 -
4
Continuity
exists
Terminals 1 -
2
No continuity
When voltage is
applied to terminals 3 -
5
Terminals 1 -
4
No continuity
Terminals 1 -
2
Continuity
exists
7B-36 Heater, Ventilator, Airconditioner (All models)
installation
1. A/C compressor relay installation
1. Install the A/C compressor relay to the fuse relay
box.
Heater, Ventilator, Airconditioner (All models) 7B-37
Ventilation duct
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below is for the tray type, excluding the front
bench seat.
Open the cover and remove the 2 screws.
Pull up the console tray and remove the 2 clips
at the front.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
Below is for 4WD except for the center console
type.
Disconnect the connector of the 4WD switch.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
3. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
4. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
5. Side cover removal
7B-38 Heater, Ventilator, Airconditioner (All models)
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
6. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
7. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
Heater, Ventilator, Airconditioner (All models) 7B-39
2. DLC
8. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag, wear gloves and
safety glasses.
After handling, wash your hands with soap.
Note
Handling of an undeployed airbag assembly
Warning
When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
When carrying the airbag, never hang the
connector or harness on your hand.
When putting down an undeployed airbag,
make sure to face the trim cover upward.
Do not place any other item on the steering
wheel with the airbag surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
If the SRS coil assembly is damaged, replace
it.
9. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
7B-40 Heater, Ventilator, Airconditioner (All models)
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
10. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
Heater, Ventilator, Airconditioner (All models) 7B-41
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
11. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
12. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
13. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
14. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
7B-42 Heater, Ventilator, Airconditioner (All models)
15. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
16. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
17. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
18. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
Heater, Ventilator, Airconditioner (All models) 7B-43
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
19. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
20. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
21. Sun sensor removal
Note
The following applies to auto A/C.
7B-44 Heater, Ventilator, Airconditioner (All models)
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
22. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
23. Center cluster removal
1. Remove the center cluster from the instrument panel.
Note
Pull out the center cluster, and then remove it.
Remove the 2 screws, and remove the center
lid cover or the tray.
24. Center ventilation grille removal
1. Remove the center ventilation grille from the
instrument panel.
Note
Remove the screw to pull out the center
ventilation grille, and then remove it.
Heater, Ventilator, Airconditioner (All models) 7B-45
25. Radio removal
1. Remove the radio from the instrument panel.
1. Radio
2. Screw
3. Screw
Note
Remove the 4 screws.
Remove the 4 screws.
Remove the connector.
26. Instrument panel cluster removal
1. Remove the instrument panel cluster from the
instrument panel.
7B-46 Heater, Ventilator, Airconditioner (All models)
1. Instrument panel cluster
27. Reinforcement removal
1. Remove the reinforcement from the instrument
panel.
Note
Remove the bolt.
1. Instrument panel 2. Reinforcement
28. Dash harness removal
1. Remove the dash harness from the reinforcement.
29. Defroster nozzle removal
1. Remove the side defroster nozzle from the defroster
nozzle.
Note
Remove the left and right sides of the defroster
nozzle.
Remove the left and right mounting screws for
the defroster nozzle.
2. Remove the defroster nozzle from the instrument
panel assembly.
Note
Remove the mounting screw for the defroster
nozzle.
30. Ventilation duct removal
1. Remove the ventilation duct side from the instrument
panel.
Note
Remove the left and right ones.
2. Remove the ventilation duct center from the
instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-47
installation
1. Ventilation duct installation
1. Install the ventilation duct center to the instrument
panel.
2. Install the ventilation duct side to the instrument
panel.
Note
Install the left and right sides.
2. Defroster nozzle installation
1. Install the defroster nozzle to the instrument panel
assembly.
Note
Install the mounting screws of the defroster
nozzle.
2. Install the side defroster nozzle to the defroster
nozzle.
Note
Install the left and right mounting screws of the
defroster nozzle.
3. Dash harness installation
1. Install the dash harness to the reinforcement.
4. Reinforcement installation
1. Install the reinforcement to the instrument panel.
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
1. Instrument panel 2. Reinforcement
5. Instrument panel cluster installation
1. Install the instrument panel cluster to the instrument
panel.
7B-48 Heater, Ventilator, Airconditioner (All models)
1. Instrument panel cluster 6. Radio installation
1. Install the radio to the instrument panel.
1. Radio
2. Screw
3. Screw
7. Center ventilation grille installation
1. Install the center ventilation grille to the instrument
panel.
Note
Put the center ventilation grille in, and install
the screws.
8. Center cluster installation
1. Install the center cluster to the instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-49
Note
Install the 2 screws and install the center lid
cover or the tray.
Fit the center cluster and install it.
9. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
10. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
11. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
7B-50 Heater, Ventilator, Airconditioner (All models)
Note
Connect the harness connector.
12. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
13. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
14. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Heater, Ventilator, Airconditioner (All models) 7B-51
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
15. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
16. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
17. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
18. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
7B-52 Heater, Ventilator, Airconditioner (All models)
19. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
20. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Steering cowl upper
2. Steering cowl lower
21. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
22. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
23. Battery ground cable connect
1. Connect the battery ground cable to the battery.
24. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
25. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-53
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
26. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
27. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
28. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
7B-54 Heater, Ventilator, Airconditioner (All models)
Note
Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
29. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
30. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
Heater, Ventilator, Airconditioner (All models) 7B-55
Evaporator core
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
3. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
4. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
5. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
6. Side cover removal
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
7B-56 Heater, Ventilator, Airconditioner (All models)
7. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
8. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
2. DLC
9. Air bag assembly safety information
Heater, Ventilator, Airconditioner (All models) 7B-57
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag, wear gloves and
safety glasses.
After handling, wash your hands with soap.
Note
Handling of an undeployed airbag assembly
Warning
When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
When carrying the airbag, never hang the
connector or harness on your hand.
When putting down an undeployed airbag,
make sure to face the trim cover upward.
Do not place any other item on the steering
wheel with the airbag surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
If the SRS coil assembly is damaged, replace
it.
10. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
7B-58 Heater, Ventilator, Airconditioner (All models)
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
11. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
Heater, Ventilator, Airconditioner (All models) 7B-59
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
12. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
13. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
14. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
15. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
7B-60 Heater, Ventilator, Airconditioner (All models)
16. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
17. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
18. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
19. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
Heater, Ventilator, Airconditioner (All models) 7B-61
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
20. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
21. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
22. Sun sensor removal
Note
The following applies to auto A/C.
7B-62 Heater, Ventilator, Airconditioner (All models)
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
23. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
24. Blower assembly removal
1. Remove the blower assembly from vehicle.
Note
Remove the 2 screws and 1 nut.
25. A/C pipe disconnect
1. Disconnect the A/C pipe from the heater evaporator
unit assembly.
Note
Remove the fitting of A/C pipe.
Remove 1 of the A/C pipe connecting bolts.
After disconnecting each pipe, put a cap or a
cover on the connection to prevent the foreign
matter from getting into the A/C pipe.
26. Heater evaporator unit assembly removal
1. Remove the heater evaporator unit assembly from
vehicle.
Heater, Ventilator, Airconditioner (All models) 7B-63
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
Note
After disconnecting each pipe, put a cap or a
cover on the connection to prevent the foreign
matter from getting into the A/C cycle.
27. Heater evaporator unit case removal
1. Remove the heater evaporator unit case from the
heater evaporator unit assembly.
Note
Remove the 11 screws, and then remove the
fitting section.
28. Evaporator core removal
1. Remove the evaporator core from the heater
evaporator unit assembly.
Note
Remove the fin sensor and the electronic
thermostat from the evaporator core.
1. Evaporator core
2. Fin sensor
3. Heater evaporator unit assembly
7B-64 Heater, Ventilator, Airconditioner (All models)
installation
1. Evaporator core installation
1. Install the evaporator core to the heater evaporator
unit assembly.
Note
Install the fin sensor and the electronic
thermostat to the evaporator core.
1. Evaporator core
2. Fin sensor
3. Heater evaporator unit assembly
2. Heater evaporator unit case installation
1. Install the heater evaporator unit case to the heater
evaporator unit assembly.
Note
Insert the fitting section, and then tighten the
11 screws.
3. Heater evaporator unit assembly installation
1. Install the heater evaporator unit assembly to vehicle.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
4. A/C pipe connect
1. Connect the A/C pipe to the heater evaporator unit
assembly.
Note
Do not reuse the O-ring of A/C pipe. Be sure to
replace with a new one.
Apply compressor oil on the O-ring.
Tighten the A/C pipe connection at the
specified torque.
Tightening torque 6.6 Nm { 0.7 kgfm / 58 lbin }
5. Blower assembly installation
1. Install the blower assembly to vehicle.
Note
Tighten the 2 screws and 1 nut.
Heater, Ventilator, Airconditioner (All models) 7B-65
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
6. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
7B-66 Heater, Ventilator, Airconditioner (All models)
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
7. Control cable connect
1. Adjust the control cable.
Note
Adjust the air source control cable.
Set the air source select lever to the "FRESH"
position on the left side.
2. Install the control cable to the blower assembly.
Note
Make sure that the control cable is firmly
fastened to the original position at the lock
clamp.
After installation, inspect the operation of the
control lever assembly.
Note
Below is for auto A/C specification.
Connect the intake actuator connector.
8. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
9. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
10. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
Heater, Ventilator, Airconditioner (All models) 7B-67
11. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
12. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
7B-68 Heater, Ventilator, Airconditioner (All models)
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
13. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
14. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
15. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
16. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
Heater, Ventilator, Airconditioner (All models) 7B-69
17. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
18. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Steering cowl upper
2. Steering cowl lower
19. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
20. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
21. Battery ground cable connect
1. Connect the battery ground cable to the battery.
22. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
23. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
7B-70 Heater, Ventilator, Airconditioner (All models)
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
24. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
25. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
26. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-71
Note
Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
27. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
28. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
2. Install the cover to the console box.
3. Install the 4WD switch to the console box.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
29. Refrigerant preparation
1. Fill refrigerant.
Note
For refilling of refrigerant, refer to the
instruction manual for the refrigerant collector.
7B-72 Heater, Ventilator, Airconditioner (All models)
Blower assembly
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below is for the tray type, excluding the front
bench seat.
Open the cover and remove the 2 screws.
Pull up the console tray and remove the 2 clips
at the front.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
Below is for 4WD except for the center console
type.
Disconnect the connector of the 4WD switch.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
3. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
4. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
5. Side cover removal
Heater, Ventilator, Airconditioner (All models) 7B-73
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
6. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
7. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
7B-74 Heater, Ventilator, Airconditioner (All models)
2. DLC
8. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag, wear gloves and
safety glasses.
After handling, wash your hands with soap.
Note
Handling of an undeployed airbag assembly
Warning
When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
When carrying the airbag, never hang the
connector or harness on your hand.
When putting down an undeployed airbag,
make sure to face the trim cover upward.
Do not place any other item on the steering
wheel with the airbag surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
If the SRS coil assembly is damaged, replace
it.
9. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
Heater, Ventilator, Airconditioner (All models) 7B-75
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
10. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
7B-76 Heater, Ventilator, Airconditioner (All models)
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
11. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
12. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
13. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
14. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
Heater, Ventilator, Airconditioner (All models) 7B-77
15. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
16. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
17. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
18. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
7B-78 Heater, Ventilator, Airconditioner (All models)
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
19. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
20. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
21. Sun sensor removal
Note
The following applies to auto A/C.
Heater, Ventilator, Airconditioner (All models) 7B-79
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
22. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
23. Blower assembly removal
1. Remove the blower assembly from vehicle.
Note
Remove the 2 screws and 1 nut.
7B-80 Heater, Ventilator, Airconditioner (All models)
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
Heater, Ventilator, Airconditioner (All models) 7B-81
installation
1. Blower assembly installation
1. Install the blower assembly to vehicle.
Note
Tighten the 2 screws and 1 nut.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
2. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
7B-82 Heater, Ventilator, Airconditioner (All models)
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
3. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
4. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
5. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
6. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
Heater, Ventilator, Airconditioner (All models) 7B-83
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
7. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
8. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
9. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
7B-84 Heater, Ventilator, Airconditioner (All models)
10. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
11. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
12. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
13. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Steering cowl upper
2. Steering cowl lower
14. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Heater, Ventilator, Airconditioner (All models) 7B-85
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
15. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
16. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
17. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
18. Instrument panel driver-side lower cover installation
1. Install the instrument panel assembly to vehicle.
19. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
20. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
21. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the 4 screws.
7B-86 Heater, Ventilator, Airconditioner (All models)
1. Glove box
2. Instrument panel assist side lower cover
22. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
23. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
Heater, Ventilator, Airconditioner (All models) 7B-87
Blower module assembly
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Glove box removal
1. Remove the glove box from the instrument panel.
Note
Remove the tabs of the hinge section.
3. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws, 4 clips and 2 tabs.
Remove the illumination light.
4. Blower module assembly removal
1. Remove the blower module assembly from the
blower assembly.
Note
Remove the harness connector.
Remove the 2 screws.
1. Blower assembly
2. Blower module assembly
7B-88 Heater, Ventilator, Airconditioner (All models)
inspection
1. Blower module assembly inspection
1. Turn ON the ignition switch.
Note
Use a digital multimeter or oscilloscope to
check the signal voltage between blower
module connector terminals No. 1 and No. 4.
Instrument set 1V/DIV, 100ms/DIV
Measurement condition
Fan switch
OFFLOHI
Note
Inspect whether the signal voltage value raises
when the blower level (OFFLOHI) is
raised.
Note
Standard waveform
Heater, Ventilator, Airconditioner (All models) 7B-89
installation
1. Blower module assembly installation
1. Install the blower module assembly to the blower
assembly.
Note
Tighten the 2 screws.
Connect the harness connector.
1. Blower assembly
2. Blower module assembly
2. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the illumination light.
Install the 4 screws, 4 clips and 2 tabs.
3. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
4. Battery ground cable connect
1. Connect the battery ground cable to the battery.
7B-90 Heater, Ventilator, Airconditioner (All models)
Blower resistor
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
3. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
4. Blower resistor removal
1. Remove the blower resistor from the blower
assembly.
Note
Remove the harness connector.
Remove the 2 screws.
1. Blower register
2. Blower assembly
Heater, Ventilator, Airconditioner (All models) 7B-91
inspection
1. Blower resistor inspection
1. Inspect the blower resistor.
Note
Disconnect the blower resistor connector.
Inspect the continuity and the resistance value
between the terminals at the blower resistor
side based on the connection table below.
1. Terminal No.
7B-92 Heater, Ventilator, Airconditioner (All models)
installation
1. Blower resistor installation
1. Install the blower resistor to the blower assembly.
Note
Tighten the 2 screws.
Connect the harness connector.
1. Blower resistor
2. Blower assembly
2. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the illumination light.
Install the 4 screws, 4 clips and 2 tabs.
3. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
4. Battery ground cable connect
1. Connect the battery ground cable to the battery.
Heater, Ventilator, Airconditioner (All models) 7B-93
Pressure switch
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Pressure switch removal
1. Remove the power steering oil tank assembly from
the power steering oil tank bracket.
Note
Lift up only the tank body and let it away
without removing the oil tank hose.
2. Disconnect the harness connector from the pressure
switch.
3. Remove the pressure switch from the A/C pipe.
Caution
Make sure to use a backup wrench when
removing the pressure switch.
After removing the pressure switch, put a cap
or a cover on the connection to prevent any
foreign object from getting into the A/C pipe.
1. Pressure switch
2. Power steering oil tank assembly
7B-94 Heater, Ventilator, Airconditioner (All models)
inspection
1. Pressure switch inspection
1. Inspect the pressure switch.
Note
When A/C is turned OFF
2. Disconnect the harness connector from the pressure
switch.
Note
Inspect the continuity between the connector
terminals at the pressure switch side.
Terminal
No.
Continuity Control
1-2 Normal open Compressor ON/OFF
Heater, Ventilator, Airconditioner (All models) 7B-95
installation
1. Pressure switch installation
1. Install the pressure switch to the A/C pipe.
2. Connect the harness connector to the pressure
switch.
Caution
When installing the pressure switch, make
sure to use a backup wrench.
Do not reuse the O-ring.
Note
Make sure to apply compressor oil to the
replaced O-ring before connecting the
connector.
Tighten the pressure switch at the specified
torque.
Tightening torque 10.8 Nm { 1.1 kgfm / 96 lb
in }
3. Install the power steering oil tank assembly to the
power steering oil tank bracket.
Note
Insert the power steering oil tank assembly
into the power steering oil tank bracket from
the upper direction.
1. Pressure switch
2. Power steering oil tank assembly
2. Refrigerant preparation
1. Fill refrigerant.
Caution
For refilling of refrigerant, refer to the
instruction manual for the refrigerant collector.
7B-96 Heater, Ventilator, Airconditioner (All models)
Mode actuator
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Glove box removal
1. Remove the glove box from the instrument panel.
Note
Remove the tabs of the hinge section.
3. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws, 4 clips and 2 tabs.
Remove the illumination light.
4. Mode actuator removal
1. Remove the mode actuator from the heater
evaporator unit assembly.
Note
Disconnect 1 of the harness connector
connections.
Remove the 2 bolts.
1. Mode actuator
2. Heater evaporator unit assembly
Heater, Ventilator, Airconditioner (All models) 7B-97
inspection
1. Mode actuator inspection
1. Inspect the mode actuator.
Note
Turn ON the ignition switch.
Use a digital multimeter or oscilloscope to
check the signal voltage between mode
actuator terminals No. 1 and No. 4.
Use an oscilloscope to check the signal
waveform output between mode actuator
terminals No. 3 and No. 2.
Operate the A/C control switch and inspect
whether the motor rotates.
Instrument set 2V/DIV, 100ms/DIV
Measurement condition Fan switch LO
Note
Waveform
Note
Signal (pulse waveform)
7B-98 Heater, Ventilator, Airconditioner (All models)
installation
1. Mode actuator installation
1. Install the mode actuator to the heater evaporator
unit assembly.
Note
Connect the rod.
Install the 2 mode actuator mounting bolts.
Connect harness connector to mode actuator.
1. Mode actuator
2. Heater evaporator unit assembly
2. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the illumination light.
Install the 4 screws, 4 clips and 2 tabs.
3. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
4. Battery ground cable connect
1. Connect the battery ground cable to the battery.
Heater, Ventilator, Airconditioner (All models) 7B-99
Control lever assembly
removal
1. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
2. Glove box removal
1. Remove the glove box from the instrument panel.
Note
Remove the tabs of the hinge section.
1. Glove box
2. Instrument panel assist side lower cover
3. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws, 4 clips and 2 tabs.
Remove the illumination light.
4. Control cable removal
1. Disconnect the control cable from the blower
assembly.
Note
Remove the control cable from the link section
of the blower assembly.
Disconnect the control cable from the lock
clamp section.
5. Control lever assembly removal
1. Remove the control lever assembly from the
instrument panel.
Note
Remove the clips at 4 corners, and pull the
control lever assembly towards you.
Disconnect the 1 harness connector and the
mode adjust cable.
1. Instrument panel
2. Control lever assembly
3. Glove box
4. Instrument panel assist side lower cover
7B-100 Heater, Ventilator, Airconditioner (All models)
inspection
1. Control lever assembly inspection
1. Inspect the control lever assembly.
Note
Inspection of fan switch
Inspect the continuity between the connector
terminals at the switch side while operating the
fan switch according to the connection table
below.
Heater, Ventilator, Airconditioner (All models) 7B-101
installation
1. Control lever assembly installation
1. Install the control lever assembly to the instrument
panel.
Note
Connect the harness connector and the mode
adjust cable.
Install the clips at 4 corners and push them.
1. Instrument panel
2. Control lever assembly
3. Glove box
4. Instrument panel assist side lower cover
2. Control cable installation
1. Adjust the control cable.
Note
Adjust the air source control cable.
Set the air source select lever to the "FRESH"
position on the left side.
7B-102 Heater, Ventilator, Airconditioner (All models)
2. Install the control cable to the blower assembly.
Note
Fix securely the control cable to the original
position.
After installation, inspect the operation of the
control lever assembly.
3. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the illumination light.
Install the 4 screws, 4 clips and 2 tabs.
4. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
5. Battery ground cable connect
1. Connect the battery ground cable to the battery.
Heater, Ventilator, Airconditioner (All models) 7B-103
Control panel assembly
removal
1. Control panel assembly removal
1. Remove the control panel assembly from the
instrument panel.
Note
Pull the clips at 4 corners towards you.
Disconnect 1 of the harness connector
connections.
1. Instrument panel
2. Control panel assembly
7B-104 Heater, Ventilator, Airconditioner (All models)
installation
1. Control panel assembly installation
1. Install the control panel assembly to the instrument
panel.
Note
Connect 1 harness connector.
Install the clips at 4 corners and push them.
1. Instrument panel
2. Control panel assembly
Heater, Ventilator, Airconditioner (All models) 7B-105
Outside air temperature sensor
removal
1. Outside air temperature sensor removal
1. Remove the outside air temperature sensor from the
front end engine hood stay.
1. Outside air temperature sensor
2. Front bumper assembly
2. Disconnect the harness connector from the outside
air temperature sensor.
Note
Remove from the space of the front bumper
fascia.
7B-106 Heater, Ventilator, Airconditioner (All models)
inspection
1. Outside air temperature sensor inspection
1. Inspect the outside air temperature sensor.
Note
Remove the outside air temperature sensor,
and measure the continuity and the resistance
value between the connector terminals No. 1
and No. 2 on the outside air temperature
sensor side.
Confirm that the resistance value gets smaller
as the ambient temperature at the temperature
sensing section of the sensor increases, and
the value gets larger as that temperature
decreases.
Terminal No. Continuity Resistance Conditions
1-2
Continuity
exists
1615 to 1785 25 { 77 F }
Heater, Ventilator, Airconditioner (All models) 7B-107
installation
1. Outside air temperature sensor installation
1. Install the outside air temperature sensor to the front
end engine hood stay.
Note
Install from the space of the front bumper
fascia.
1. Outside air temperature sensor
2. Front bumper assembly
2. Connect the harness connector to the outside air
temperature sensor.
7B-108 Heater, Ventilator, Airconditioner (All models)
Condenser assembly
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Intercooler safety information
Caution
If oil builds up inside the intercooler, remove
the drain plug to drain the oil.
1. Remove the drain plug from the intercooler.
Note
Put the hand into the bumper opening and
remove the drain plug with a tool.
2. Drain the engine oil from the intercooler.
Note
Prepare a shop cloth under the drain plug to
catch the drained oil with it.
3. Install the drain plug to the intercooler.
Note
Confirm that the engine oil has been drained
before installing the drain plug.
Tightening torque 1.2 Nm { 0.12 kgfm / 10.6 lb
in }
3. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
4. Radiator grille removal
1. Remove the radiator grille from vehicle.
Note
Remove the screws.
Remove the 4 clips.
1. Screw
2. Clip
5. Front bumper assembly removal
1. Remove the front bumper assembly from vehicle.
Note
Remove the 10 clips.
6. Front bumper impact bar assembly removal
1. Remove the bumper seal from vehicle.
Note
Remove the 6 clips on one side.
Heater, Ventilator, Airconditioner (All models) 7B-109
1. Upper bumper seal
2. Lower bumper seal
2. Remove the front bumper support from vehicle.
3. Remove the front bumper impact bar assembly from
vehicle.
7. Front end engine hood stay removal
1. Remove the front end engine hood stay from the
frame.
8. Intercooler removal
1. Disconnect the intake air hose from the intercooler.
Note
Disconnect it at both the turbocharger and
intake throttle sides.
7B-110 Heater, Ventilator, Airconditioner (All models)
1. Intake hose, turbocharger side
2. Intake hose, intake throttle side
2. Remove the intercooler from the frame.
9. Horn removal
1. Remove the horn from vehicle.
Note
Remove 1 bolt each from the left and right.
10. Engine hood lock cover removal
1. Remove the engine hood lock cover from vehicle.
Note
Remove the 3 clips.
11. Engine hood lock removal
1. Remove the engine hood lock from vehicle.
Note
Remove the 2 bolts.
12. Radiator upper mounting bracket removal
1. Remove the from vehicle.
Note
Remove 1 bolt each from the left and right.
13. Condenser upper bracket removal
1. Remove the from vehicle.
Note
Remove the bolts 1 by 1.
14. Radiator support assembly removal
1. Remove the from vehicle.
Note
Remove the 8 bolts and the 5 engine room
harness mounting clips.
1. Condenser upper bracket
2. Condenser assembly
3. Radiator support assembly
15. A/C hose and A/C pipe removal
1. Remove the from the condenser assembly.
Note
Remove the 1 bolt.
After disconnecting the A/C pipe, put a cap or
cover on the connection to prevent any foreign
object from getting into the A/C pipe.
16. Condenser assembly removal
1. Remove the condenser assembly from vehicle.
Heater, Ventilator, Airconditioner (All models) 7B-111
installation
1. Condenser assembly installation
1. Install the condenser assembly to vehicle.
Note
When installing a new condenser assembly,
add 30 cm3 {0.85 lmp fl oz} of compressor oil.
2. A/C hose and A/C pipe installation
1. Connect the to the condenser assembly.
Caution
Do not reuse the O-ring, and a new one should
be used.
Note
Make sure to apply a layer of compressor oil to
the replaced O-ring before connecting the A/C
pipe.
Tighten the A/C hose and 1 A/C pipe mounting
bolt at the specified torque.
Tightening torque 15 Nm { 1.5 kgfm / 11 lbft }
Note
Install the A/C pipe mounting clamp.
3. Radiator support assembly installation
1. Install the to vehicle.
Note
Install the engine room harness with the 5 clips
and tighten the 8 mounting bolts.
1. Condenser upper bracket
2. Condenser assembly
3. Radiator support assembly
4. Condenser upper bracket installation
1. Install the to vehicle.
Note
Tighten 1 bolt each for the left and right.
5. Radiator upper mounting bracket installation
1. Install the to vehicle.
Note
Tighten 1 bolt each for the left and right.
6. Engine hood lock installation
1. Install the engine hood lock to vehicle.
Note
Tighten the 2 bolts.
7. Engine hood lock cover installation
1. Install the engine hood lock cover to vehicle.
Note
Install with the 3 clips.
8. Horn installation
1. Install the horn to vehicle.
Note
Tighten 1 bolt each for the left and right.
9. Intercooler installation
1. Install the intercooler to the frame.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
2. Connect the intake air hose to the intercooler.
Note
Connect it at both the turbocharger and intake
throttle sides.
Tightening torque 6 Nm { 0.6 kgfm / 53 lbin }
Clamp
7B-112 Heater, Ventilator, Airconditioner (All models)
Tightening torque 5 Nm { 0.5 kgfm / 44 lbin }
Duct
1. Intake hose, turbocharger side
2. Intake hose, intake throttle side
10. Front end engine hood stay installation
1. Install the front end engine hood stay to the frame.
11. Front bumper impact bar assembly installation
1. Install the front bumper impact bar assembly to
vehicle.
Note
Tighten the fixing bolt to the specified torque.
Tightening torque 62 Nm { 6.3 kgfm / 46 lbft }
2. Install the front bumper support to vehicle.
3. Install the bumper seal to vehicle.
Note
Install the 6 clips on one side.
Heater, Ventilator, Airconditioner (All models) 7B-113
1. Upper bumper seal
2. Lower bumper seal
12. Front bumper assembly installation
1. Install the front bumper assembly to vehicle.
Note
Install the 10 clips.
13. Radiator grille installation
1. Install the radiator grille to vehicle.
Note
Put the claw of the radiator grille in the
installation hole of the front bumper shown in
the diagram.
1. Radiator grille
Note
Install the 4 clips.
Install the screws.
1. Screw
2. Clip
14. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
15. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
7B-114 Heater, Ventilator, Airconditioner (All models)
Center ventilation grille
removal
1. Control panel assembly removal
1. Remove the control panel assembly from the
instrument panel.
Note
Remove the clips at 4 corners, and pull the
control panel assembly towards you.
Disconnect 1 of the harness connector
connections.
1. Instrument panel
2. Control panel assembly
2. Center cluster removal
1. Remove the center cluster from the instrument panel.
Note
Pull out the center cluster, and then remove it.
Remove the 2 screws, and remove the center
lid cover or the tray.
3. Center ventilation grille removal
1. Remove the center ventilation grille from the
instrument panel.
Note
Remove the screw to pull out the center
ventilation grille, and then remove it.
Heater, Ventilator, Airconditioner (All models) 7B-115
installation
1. Center ventilation grille installation
1. Install the center ventilation grille to the instrument
panel.
Note
Put the center ventilation grille in, and install
the screws.
2. Center cluster installation
1. Install the center cluster to the instrument panel.
Note
Install the 2 screws and install the center lid
cover or the tray.
Put the center cluster in and install it.
3. Control panel assembly installation
1. Install the control panel assembly to the instrument
panel.
Note
Connect the harness connector.
Install the clips at 4 corners.
1. Instrument panel
2. Control panel assembly
7B-116 Heater, Ventilator, Airconditioner (All models)
Center vent grille with manual air conditioning
removal
1. Glove box removal
1. Remove the glove box from the instrument panel.
Note
Remove the tabs of the hinge section.
2. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws, 4 clips and 2 tabs.
Remove the illumination light.
3. Control lever assembly removal
1. Remove the control lever assembly from the
instrument panel.
Note
Remove the control cable from the link section
of the blower assembly.
Disconnect the control cable from the lock
clamp section.
Remove the clips at 4 corners, and pull the
control lever assembly towards you.
Disconnect the 1 harness connector and the
mode adjust cable.
4. Center cluster removal
1. Remove the center cluster from the instrument panel.
Note
Pull out the center cluster, and then remove it.
Remove the 2 screws, and remove the center
lid cover or the tray.
5. Center vent grille with manual air conditioning
removal
1. Remove the center ventilation grille (manual) from
the instrument panel.
Note
Remove the 4 clips and 3 tabs.
Heater, Ventilator, Airconditioner (All models) 7B-117
installation
1. Center vent grille with manual air conditioning
installation
1. Install the center ventilation grille (manual) to the
instrument panel.
Note
Install the 4 clips and 3 tabs.
2. Center cluster installation
1. Install the center cluster to the instrument panel.
Note
Install the 2 screws and install the center lid
cover or the tray.
Fit the center cluster and install it.
3. Control lever assembly installation
1. Install the control lever assembly to the instrument
panel.
Note
Connect the harness connector and the mode
adjust cable.
Install the clips at 4 corners and push them.
Connect the control cable to the blower
assembly.
Connect the control cable to the lock clamp
section.
Install the control cable to the link section of
the blower assembly.
4. Instrument panel assist-side lower cover installation
1. Install the instrument panel lower assist panel to the
instrument panel.
Note
Install the illumination light.
5. Glove box installation
1. Install the glove box to the instrument panel.
Note
Install the tabs of the hinge section.
7B-118 Heater, Ventilator, Airconditioner (All models)
Blower motor relay
removal
1. Blower motor relay removal
1. Remove the blower motor relay from the fuse relay
box.
1. A/C compressor relay
2. Blower motor relay
3. A/C fuse
Heater, Ventilator, Airconditioner (All models) 7B-119
inspection
1. Blower motor relay inspection
1. Inspect the blower motor relay using tester.
Note
Inspect the continuity between the terminals at
the blower motor relay side.
Continuity inspection
When voltage is not
applied to terminals 3 -
5
Terminals 1 -
4
Continuity
exists
Terminals 1 -
2
No continuity
When voltage is
applied to terminals 3 -
5
Terminals 1 -
4
No continuity
Terminals 1 -
2
Continuity
exists
7B-120 Heater, Ventilator, Airconditioner (All models)
installation
1. Blower motor relay installation
1. Install the blower motor relay to the fuse relay box.
Heater, Ventilator, Airconditioner (All models) 7B-121
Case assembly
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
2. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below is for the tray type, excluding the front
bench seat.
Open the cover and remove the 2 screws.
Pull up the console tray and remove the 2 clips
at the front.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
Below is for 4WD except for the center console
type.
Disconnect the connector of the 4WD switch.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
3. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
4. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
7B-122 Heater, Ventilator, Airconditioner (All models)
2. Instrument panel assist side lower cover
5. Side cover removal
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
6. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
7. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
Heater, Ventilator, Airconditioner (All models) 7B-123
1. Instrument panel driver side lower cover
2. DLC
8. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag assembly, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag
assembly.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag assembly, wear
gloves and safety glasses.
After handling, wash your hands with soap.
Note
Handling of a undeployed airbag assembly
Warning
When carrying an undeployed airbag
assembly, make sure that the trim cover faces
the opposite direction of your body.
When carrying the airbag assembly, never
hang the connector or harness on your hand.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Do not place any other item on the steering
wheel with the airbag assembly surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
9. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
7B-124 Heater, Ventilator, Airconditioner (All models)
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
10. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
Heater, Ventilator, Airconditioner (All models) 7B-125
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
11. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
12. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
13. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
14. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
7B-126 Heater, Ventilator, Airconditioner (All models)
15. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
16. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
17. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
18. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
Heater, Ventilator, Airconditioner (All models) 7B-127
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
19. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
20. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
21. Sun sensor removal
Note
The following applies to auto A/C.
7B-128 Heater, Ventilator, Airconditioner (All models)
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
22. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
23. Blower assembly removal
1. Remove the blower assembly from vehicle.
Note
Remove the 2 screws and 1 nut.
Heater, Ventilator, Airconditioner (All models) 7B-129
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
24. Case assembly removal
1. Remove the case assembly from the blower
assembly.
Note
Remove the fitting section.
Remove the actuator, mode lever, and lining
from the case assembly.
1. Case assembly
2. Lining
3. Mode lever
4. Intake actuator
5. Blower assembly
7B-130 Heater, Ventilator, Airconditioner (All models)
installation
1. Case assembly installation
1. Install the case assembly to the blower assembly.
Note
Insert the fitting section.
Install the actuator, mode lever, and lining to
the case assembly.
1. Case assembly
2. Lining
3. Mode Lever
4. Intake actuator
5. Blower assembly
2. Blower assembly installation
1. Install the blower assembly to vehicle.
Note
Tighten the 2 screws and 1 nut.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
3. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Heater, Ventilator, Airconditioner (All models) 7B-131
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
4. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
5. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
6. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
7B-132 Heater, Ventilator, Airconditioner (All models)
7. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
8. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
Heater, Ventilator, Airconditioner (All models) 7B-133
9. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
10. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
11. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
12. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
13. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
14. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
7B-134 Heater, Ventilator, Airconditioner (All models)
1. Steering cowl upper
2. Steering cowl lower
15. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
16. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
17. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
18. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
19. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note
Connect the switch connector.
Install the DLC.
Heater, Ventilator, Airconditioner (All models) 7B-135
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
20. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
21. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
22. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
7B-136 Heater, Ventilator, Airconditioner (All models)
Note
Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
23. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
24. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
Heater, Ventilator, Airconditioner (All models) 7B-137
Fin sensor
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
3. Raise vehicle using the jack.
3. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below is for the tray type, excluding the front
bench seat.
Open the cover and remove the 2 screws.
Pull up the console tray and remove the 2 clips
at the front.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
Below is for 4WD except for the center console
type.
Disconnect the connector of the 4WD switch.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
4. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
5. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
7B-138 Heater, Ventilator, Airconditioner (All models)
1. Glove box
2. Instrument panel assist side lower cover
6. Side cover removal
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
7. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
8. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Heater, Ventilator, Airconditioner (All models) 7B-139
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
2. DLC
9. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag, wear gloves and
safety glasses.
After handling, wash your hands with soap.
Note
Handling of an undeployed airbag assembly
Warning
When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
When carrying the airbag, never hang the
connector or harness on your hand.
When putting down an undeployed airbag,
make sure to face the trim cover upward.
Do not place any other item on the steering
wheel with the airbag surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
If the SRS coil assembly is damaged, replace
it.
10. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
7B-140 Heater, Ventilator, Airconditioner (All models)
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
11. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
Heater, Ventilator, Airconditioner (All models) 7B-141
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
12. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
13. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
14. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
15. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
7B-142 Heater, Ventilator, Airconditioner (All models)
16. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
17. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
18. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
19. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
Heater, Ventilator, Airconditioner (All models) 7B-143
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
20. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
21. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
22. Sun sensor removal
Note
The following applies to auto A/C.
7B-144 Heater, Ventilator, Airconditioner (All models)
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
23. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
24. Blower assembly removal
1. Remove the blower assembly from vehicle.
Note
Remove the 2 screws and 1 nut.
Heater, Ventilator, Airconditioner (All models) 7B-145
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
25. A/C pipe removal
1. Disconnect the A/C pipe from the heater evaporator
unit assembly.
Note
Remove the fitting of A/C pipe.
Remove 1 of the A/C pipe connecting bolts.
After disconnecting each pipe, put a cap or a
cover on the connection to prevent the foreign
matter from getting into the A/C pipe.
26. Heater evaporator unit assembly removal
1. Remove the heater evaporator unit assembly from
vehicle.
1. Evaporator core
2. Electronic thermostat
3. Heater evaporator unit assembly
4. Heater evaporator unit case
27. Heater evaporator unit case removal
1. Remove the heater evaporator unit case from the
heater evaporator unit assembly.
Note
Remove the 11 screws, and then remove the
fitting section.
28. Evaporator core removal
1. Remove the evaporator core from the heater
evaporator unit assembly.
Note
Remove the fin sensor from the evaporator
core.
1. Evaporator core
2. Fin sensor
3. Heater evaporator unit assembly
29. Fin sensor removal
1. Remove the fin sensor from the evaporator core.
7B-146 Heater, Ventilator, Airconditioner (All models)
installation
1. Fin sensor installation
1. Install the fin sensor to the evaporator core.
2. Evaporator core installation
1. Install the evaporator core to the heater evaporator
unit assembly.
1. Evaporator core
2. Fin sensor
3. Heater evaporator unit assembly
3. Heater evaporator unit case installation
1. Install the heater evaporator unit case to the heater
evaporator unit assembly.
Note
Insert the fitting section, and then tighten the
11 screws.
4. Heater evaporator unit assembly installation
1. Install the heater evaporator unit assembly to vehicle.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
5. A/C pipe installation
1. Install the A/C pipe to the heater evaporator unit
assembly.
Note
Do not reuse the O-ring.
Always replace them with new ones.
Make sure to apply compressor oil to the
replaced O-ring before connecting the hose.
Tighten the A/C pipe mounting bolt at the
specified torque.
Tightening torque 15 Nm { 1.5 kgfm / 11 lbft }
6. Blower assembly installation
1. Install the blower assembly to vehicle.
Note
Tighten the 2 screws and 1 nut.
Heater, Ventilator, Airconditioner (All models) 7B-147
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
7. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
7B-148 Heater, Ventilator, Airconditioner (All models)
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
8. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
9. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
10. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
11. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
Heater, Ventilator, Airconditioner (All models) 7B-149
1. Front sill plate
2. Rear sill plate
3. Clip
12. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
13. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
14. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
15. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
16. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
7B-150 Heater, Ventilator, Airconditioner (All models)
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
17. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
18. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Steering cowl upper
2. Steering cowl lower
19. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
20. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Heater, Ventilator, Airconditioner (All models) 7B-151
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
21. Battery ground cable installation
1. Install the battery ground cable to the battery.
22. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
23. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
Note
Install the 2 fixing screws.
7B-152 Heater, Ventilator, Airconditioner (All models)
1. Hood lock control lever
2. Control cable
3. Screw
24. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
25. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
26. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
27. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
28. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Heater, Ventilator, Airconditioner (All models) 7B-153
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
7B-154 Heater, Ventilator, Airconditioner (All models)
Electronic thermostat
removal
1. Refrigerant preparation
1. Collect refrigerant.
Caution
For collection of refrigerant, refer to the
instruction manual for the refrigerant collector.
2. Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
3. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
4. Glove box removal
1. Remove the glove box from the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
5. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
6. Side cover removal
1. Remove the side cover from the instrument panel.
Heater, Ventilator, Airconditioner (All models) 7B-155
Note
Remove the left and right side covers.
7. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
8. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
2. DLC
7B-156 Heater, Ventilator, Airconditioner (All models)
9. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag, wear gloves and
safety glasses.
After handling, wash your hands with soap.
Note
Handling of an undeployed airbag assembly
Warning
When carrying an undeployed airbag, make
sure that the trim cover faces the opposite
direction of your body.
When carrying the airbag, never hang the
connector or harness on your hand.
When putting down an undeployed airbag,
make sure to face the trim cover upward.
Do not place any other item on the steering
wheel with the airbag surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
If the SRS coil assembly is damaged, replace
it.
10. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Note
Confirm the lever position in the hole in the
following illustration.
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
Heater, Ventilator, Airconditioner (All models) 7B-157
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
Failure to follow this procedure may result in
personal injury.
11. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
7B-158 Heater, Ventilator, Airconditioner (All models)
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
12. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
13. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
14. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
15. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
Heater, Ventilator, Airconditioner (All models) 7B-159
16. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
17. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
18. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
19. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
7B-160 Heater, Ventilator, Airconditioner (All models)
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
20. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
21. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
22. Sun sensor removal
Note
The following applies to auto A/C.
Heater, Ventilator, Airconditioner (All models) 7B-161
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
23. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
24. Blower assembly removal
1. Remove the blower assembly from vehicle.
Note
Remove the 2 screws and 1 nut.
7B-162 Heater, Ventilator, Airconditioner (All models)
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
25. A/C pipe removal
1. Disconnect the A/C pipe from the heater evaporator
unit assembly.
Note
Remove the fitting of A/C pipe.
Remove 1 of the A/C pipe connecting bolts.
After disconnecting each pipe, put a cap or a
cover on the connection to prevent the foreign
matter from getting into the A/C pipe.
26. Heater evaporator unit assembly removal
1. Remove the heater evaporator unit assembly from
vehicle.
1. Evaporator core
2. Electronic thermostat
3. Heater evaporator unit assembly
4. Heater evaporator unit case
27. Heater evaporator unit case removal
1. Remove the heater evaporator unit case from the
heater evaporator unit assembly.
Note
Remove the 11 screws, and then remove the
fitting section.
28. Evaporator core removal
1. Remove the evaporator core from the heater
evaporator unit assembly.
1. Evaporator core
2. Electronic thermostat
3. Heater evaporator unit assembly
4. Heater evaporator unit case
29. Electronic thermostat removal
1. Remove the electronic thermostat from the
evaporator core.
Heater, Ventilator, Airconditioner (All models) 7B-163
inspection
1. Electronic thermostat inspection
1. Inspect the electronic thermostat.
Note
Turn ON the ignition switch.
Set the vent selector knob to "FACE" and the
air selector lever to "RECIRC" to operate the
air conditioner.
Set the temperature control knob to
"MAXCOOL" and inspect the magnet clutch
turns ON and OFF.
Turn on the engine and inspect whether the
voltage between terminals No. 1 and No. 3 is
12V.
When the magnet clutch turns on and off,
measure the voltage between connector
terminals No. 1 and No. 2.
Terminal
No.
Magnetic clutch Voltage
1-2
ON 0 V
OFF 12 V
7B-164 Heater, Ventilator, Airconditioner (All models)
installation
1. Electronic thermostat installation
1. Install the electronic thermostat to the evaporator
core.
2. Evaporator core installation
1. Install the evaporator core to the heater evaporator
unit assembly.
1. Evaporator core
2. Electronic thermostat
3. Heater evaporator unit assembly
4. Heater evaporator unit case
3. Heater evaporator unit case installation
1. Install the heater evaporator unit case to the heater
evaporator unit assembly.
Note
Insert the fitting section, and then tighten the
11 screws.
4. Heater evaporator unit assembly installation
1. Install the heater evaporator unit assembly to vehicle.
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
5. A/C pipe installation
1. Install the A/C pipe to the heater evaporator unit
assembly.
Note
Do not reuse the O-ring.
Always replace them with new ones.
Make sure to apply compressor oil to the
replaced O-ring before connecting the hose.
Tighten the A/C pipe mounting bolt at the
specified torque.
Tightening torque 15 Nm { 1.5 kgfm / 11 lbft }
6. Blower assembly installation
1. Install the blower assembly to vehicle.
Note
Tighten the 2 screws and 1 nut.
Heater, Ventilator, Airconditioner (All models) 7B-165
1. Nut
2. Blower assembly
3. Screw
4. Heater evaporator unit assembly
7. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
7B-166 Heater, Ventilator, Airconditioner (All models)
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
8. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
9. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
10. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
11. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
Heater, Ventilator, Airconditioner (All models) 7B-167
1. Front sill plate
2. Rear sill plate
3. Clip
12. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
13. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
14. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
15. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
16. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
7B-168 Heater, Ventilator, Airconditioner (All models)
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
17. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
18. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Steering cowl upper
2. Steering cowl lower
19. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
20. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Heater, Ventilator, Airconditioner (All models) 7B-169
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
21. Battery ground cable connect
1. Connect the battery ground cable to the battery.
22. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
23. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
Note
Install the 2 fixing screws.
7B-170 Heater, Ventilator, Airconditioner (All models)
1. Hood lock control lever
2. Control cable
3. Screw
24. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
25. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
26. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
27. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
28. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Heater, Ventilator, Airconditioner (All models) 7B-171
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
7B-172 Heater, Ventilator, Airconditioner (All models)
Defroster nozzle
removal
1. Battery ground cable disconnect
1. Open the engine hood assembly.
2. Disconnect the battery ground cable from the battery.
2. Console box removal
Note
Below is for the center console type manual
transmission.
1. Remove the shift lever knob from the shift lever.
Note
Below is for the center console type.
2. Remove the shift console cover from the console
box.
Note
Disconnect the cigarette lighter connector.
Below is for the 2WD center console type.
3. Remove the cover from the console box.
Note
Below is for the 4WD center console type.
4. Remove the 4WD switch from the console box.
Note
Below is for the center console type.
5. Remove the console box from the floor.
Note
Remove the 3 clips.
Open the console box cover and remove 2
screws.
Remove the control box backward.
Below is for the tray type, excluding the front
bench seat.
Open the cover and remove the 2 screws.
Pull up the console tray and remove the 2 clips
at the front.
Below except for the center console type.
6. Remove the console cover from the instrument
panel.
Note
Remove the 2 clips.
Disconnect the cigarette lighter connector.
Below is for 4WD except for the center console
type.
Disconnect the connector of the 4WD switch.
7. Remove the cup holder cover from the floor.
8. Remove the bracket from the floor.
3. Glove box removal
1. Remove the glove box from the instrument panel.
2. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
Note
Disconnect the passenger airbag harness
connector.
3. Remove the assist side lid cover from the instrument
panel.
Heater, Ventilator, Airconditioner (All models) 7B-173
1. Passenger airbag harness connector
2. Assist side rid cover
4. Instrument panel assist-side lower cover removal
1. Remove the instrument panel assist-side lower cover
from the instrument panel.
Note
Remove the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
5. Side cover removal
1. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
6. Meter cluster removal
1. Remove the meter cluster from the instrument panel.
Note
Pull out 4 clips from the instrument panel.
Disconnect the switch connector.
1. Clip
7. Instrument panel driver-side lower cover removal
1. Remove the hood lock control lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Remove the 2 fixing screws.
7B-174 Heater, Ventilator, Airconditioner (All models)
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Remove the instrument panel driver-side lower cover
from the instrument panel.
Note
Pull out the instrument panel driver side lower
cover.
Disconnect the switch connector.
Remove the DLC.
1. Instrument panel driver side lower cover
2. DLC
8. Air bag assembly safety information
Note
Handling of a deployed airbag assembly
Warning
When handling the airbag assembly, the safety
precautions must be observed.
A small amount of sodium hydroxide may be
contained on the surface of a deployed airbag
assembly.
This is a by-product of the deployment reaction
and may cause irritation when it contacts with
skin or eye.
To handle activated airbag assembly, wear
gloves and safety glasses.
After handling, wash your hands with soap.
Note
Handling of a undeployed airbag assembly
Warning
When carrying an undeployed airbag
assembly, make sure that the trim cover faces
the opposite direction of your body.
When carrying the airbag assembly, never
hang the connector or harness on your hand.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Do not place any other item on the steering
wheel with the airbag assembly surface facing
downward.
Not following this procedure will result in a fire
or injuries.
Caution
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
After the airbag is deployed, inspect for
burning due to overheating, melting or other
problems.
9. Driver air bag assembly removal
Note
Confirm the holes on the both sides of the
steering cover.
Heater, Ventilator, Airconditioner (All models) 7B-175
Note
Confirm the lever position in the hole in the
following illustration.
Note
Insert a bar of diameter 6 mm {0.24 in} to
remove the driver airbag assembly from the
lever.
1. Remove the driver air bag assembly from the
steering wheel.
2. Disconnect the connector from the driver air bag
assembly.
Note
Disconnect the airbag connector.
Disconnect the horn connector.
1. Airbag connector
2. Horn connector
Warning
Keep the airbag assembly away from your
body when carrying it.
When putting down an undeployed airbag
assembly, make sure to face the trim cover
upward.
Place the trim cover upward on a flat surface.
7B-176 Heater, Ventilator, Airconditioner (All models)
Failure to follow this procedure may result in
personal injury.
10. Steering wheel removal
Note
Reconfirm that the steering wheel is set to the
position for advancing straight forward.
Make setting marks on the steering wheel and
shaft.
They are used for reassembly of parts.
1. Remove the nut from the steering shaft.
2. Remove the steering wheel from the steering shaft
using special tool.
SST: 5-8521-0016-0 - steering wheel remover
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to remove it.
The steering shaft is designed to absorb
shocks.
11. Steering cowl removal
1. Remove the steering cowl from the steering column.
1. Steering cowl upper
2. Steering cowl lower
Heater, Ventilator, Airconditioner (All models) 7B-177
12. Assist side lid cover removal
1. Remove the assist side lid cover from the instrument
panel.
13. Cover removal
Note
The following applies to models without
passenger airbag.
1. Remove the cover from the instrument panel.
14. Passenger air bag assembly removal
1. Remove the passenger air bag assembly from the
instrument panel.
Note
Remove the 2 bolts.
1. Passenger airbag mounting bolts
Caution
Remove carefully as claws are attached.
15. Door finisher removal
Note
The following applies to regular cab and
extend cab.
1. Remove the door finisher from the body.
16. Front door finisher removal
Note
The following applies to crew cab.
1. Remove the front door finisher from the body.
17. Front pillar trim cover removal
1. Remove the front pillar trim cover from the front
pillar.
Note
The following applies to models without assist
grip.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
7B-178 Heater, Ventilator, Airconditioner (All models)
Note
The following applies to models with assist
grip.
Remove the assist grip.
Open the cover and remove the screw.
Remove the clip from the body panel.
Remove the front pillar trim cover by pulling its
lower part upward.
18. Sill plate removal
1. Remove the sill plate from the floor.
Note
Remove clips from the body panel.
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
1. Sill plate
2. Clip
Note
Crew cab
Heater, Ventilator, Airconditioner (All models) 7B-179
1. Front sill plate
2. Rear sill plate
3. Clip
19. Dash side trim pad removal
1. Remove the dash side trim pad from the body.
Note
Remove the nut.
Remove the trim cover clip from the body
panel.
20. Front cover removal
Note
The following applies except for auto A/C.
1. Remove the front cover from the instrument panel.
21. Sun sensor removal
Note
The following applies to auto A/C.
1. Remove the sun sensor from the instrument panel.
Note
Disconnect the harness connector.
22. Instrument panel removal
1. Remove the speaker grille from the instrument panel.
Note
Remove the left and right speaker grilles.
2. Remove the side cover from the instrument panel.
Note
Remove the left and right side covers.
3. Remove the instrument panel assembly and
reinforcement from vehicle.
Note
Remove the 4 bolts that fix the steering
column to the reinforcement.
Note
Disconnect the control cable of the blower unit
and the ventilation unit.
Disconnect the dash harness connector.
Remove the bolt and nut that secure the
instrument panel and reinforcement assembly.
7B-180 Heater, Ventilator, Airconditioner (All models)
23. Center cluster removal
1. Remove the center cluster from the instrument panel.
Note
Pull out the center cluster, and then remove it.
Remove the 2 screws, and remove the center
lid cover or the tray.
24. Center ventilation grille removal
1. Remove the center ventilation grille from the
instrument panel.
Note
Remove the screw to pull out the center
ventilation grille, and then remove it.
25. Radio removal
Note
The following applies to models with radio.
1. Remove the radio from the instrument panel.
26. Instrument panel cluster removal
1. Remove the instrument panel cluster from the
instrument panel.
1. Instrument panel cluster
27. Reinforcement removal
1. Remove the reinforcement from the instrument
panel.
Note
Remove the bolt.
Heater, Ventilator, Airconditioner (All models) 7B-181
1. Instrument panel 2. Reinforcement
28. Dash harness removal
1. Remove the dash harness from the reinforcement.
29. Defroster nozzle removal
1. Remove the side defroster nozzle from the defroster
nozzle.
Note
Remove the left and right sides of the defroster
nozzle.
Remove the left and right mounting screws for
the defroster nozzle.
2. Remove the defroster nozzle from the instrument
panel assembly.
Note
Remove the mounting screw for the defroster
nozzle.
7B-182 Heater, Ventilator, Airconditioner (All models)
installation
1. Defroster nozzle installation
1. Install the defroster nozzle to the instrument panel
assembly.
Note
Install the mounting screws of the defroster
nozzle.
2. Install the side defroster nozzle to the defroster
nozzle.
Note
Install the left and right mounting screws of the
defroster nozzle.
2. Dash harness installation
1. Install the dash harness to the reinforcement.
3. Reinforcement installation
1. Install the reinforcement to the instrument panel.
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
1. Instrument panel 2. Reinforcement
4. Instrument panel cluster installation
1. Install the instrument panel cluster to the instrument
panel.
1. Instrument panel cluster
5. Radio installation
Note
The following applies to models with radio.
1. Install the radio to the instrument panel.
Note
Connect the harnesses.
6. Center ventilation grille installation
1. Install the center ventilation grille to the instrument
panel.
Note
Put the center ventilation grille in, and install
the screws.
Heater, Ventilator, Airconditioner (All models) 7B-183
7. Center cluster installation
1. Install the center cluster to the instrument panel.
Note
Install the 2 screws and install the center lid
cover or the tray.
Put the center cluster in and install it.
8. Instrument panel installation
1. Install the instrument panel assembly and
reinforcement to vehicle.
Note
Tighten the bolts and nuts that secure the
instrument panel and reinforcement assembly
to the specified torque.
Tightening torque 19 Nm { 1.9 kgfm / 14 lbft }
Bolt
Tightening torque 8 Nm { 0.8 kgfm / 6 lbft }
Nut
Note
Tighten the 4 bolts that secure the steering
column to the reinforcement to the specified
torque.
Tightening torque 20 Nm { 2.0 kgfm / 15 lbft }
Steering column bolt
7B-184 Heater, Ventilator, Airconditioner (All models)
Note
Connect the dash harness connector.
Connect the control cable of the blower unit
and ventilation unit.
2. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
3. Install the speaker grille to the instrument panel.
Note
Install the left and right speaker grilles.
9. Front cover installation
Note
The following applies except for auto A/C.
1. Install the front cover to the instrument panel.
10. Sun sensor installation
Note
The following applies to auto A/C.
1. Install the sun sensor to the instrument panel.
Note
Connect the harness connector.
11. Dash side trim pad installation
1. Install the dash side trim pad to the body.
Note
Install the nut.
12. Sill plate installation
1. Install the sill plate to the floor.
Note
Regular cab
1. Sill plate
2. Clip
Note
Extend cab
Heater, Ventilator, Airconditioner (All models) 7B-185
1. Sill plate
2. Clip
Note
Crew cab
1. Front sill plate
2. Rear sill plate
3. Clip
13. Front pillar trim cover installation
1. Install the front pillar trim cover to the front pillar.
Note
The following applies to models without assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Note
The following applies to models with assist
grip.
Insert the lower part of the front pillar trim
cover, and install the clip to the body panel.
Install the assist grip.
Install the 2 fixing screws and close the cover.
14. Door finisher installation
Note
The following applies to regular cab and
extend cab.
1. Install the door finisher to the body.
15. Front door finisher installation
Note
The following applies to crew cab.
1. Install the front door finisher to the body.
7B-186 Heater, Ventilator, Airconditioner (All models)
16. Cover installation
Note
The following applies to models without
passenger airbag.
1. Install the cover to the instrument panel.
17. Passenger air bag assembly installation
1. Install the passenger air bag assembly to the
instrument panel.
Note
Press the portion indicated by the arrow in the
illustration to install it to the instrument panel.
Securely fit the claws.
Note
Install the 2 bolts.
Tightening torque 25 Nm { 2.5 kgfm / 18 lbft }
1. Passenger airbag mounting bolts
18. Assist side lid cover installation
1. Install the assist side lid cover to the instrument
panel.
19. Steering cowl installation
1. Install the steering cowl to the steering column.
Caution
When installing the steering cowl, be careful
not to pinch the harness by the cowl.
1. Steering cowl upper
2. Steering cowl lower
20. Steering wheel installation
1. Install the steering wheel to the steering shaft.
Note
Line up the setting applied during removal, and
install the steering wheel.
Heater, Ventilator, Airconditioner (All models) 7B-187
Caution
Never apply an impact to the steering wheel
with a hammer, etc. to install it.
The steering shaft is designed to absorb
shocks.
2. Install the nut to the steering shaft.
Tightening torque 35 Nm { 3.6 kgfm / 26 lbft }
21. Driver air bag assembly installation
1. Install the connector to the driver air bag assembly.
Note
Connect the airbag connector.
Connect the horn connector.
1. Airbag connector
2. Horn connector
2. Install the driver air bag assembly to the steering
wheel.
22. Battery ground cable connect
1. Connect the battery ground cable to the battery.
2. Close the engine hood assembly.
3. Lower vehicle.
23. SRS control unit setting
1. Reactivate the SRS function.
Note
Install the SRS fuse to the fuse relay box or
connect the battery ground cable to the
battery.
Turn the ignition switch on, and confirm that
the SRS airbag warning light turns off after
blinking 7 times.
24. Instrument panel driver-side lower cover installation
1. Install the instrument panel driver-side lower cover
to the instrument panel.
Note
Connect the switch connector.
Install the DLC.
1. Instrument panel driver side lower cover
2. DLC
2. Remove the fuel filler lid opener lever from the
instrument panel driver-side lower cover.
Note
Install the 2 fixing screws.
1. Fuel filler rid opener lever
2. Fuel filler rid cable
3. Screw
3. Install the hood lock control lever to the instrument
panel driver-side lower cover.
7B-188 Heater, Ventilator, Airconditioner (All models)
Note
Install the 2 fixing screws.
1. Hood lock control lever
2. Control cable
3. Screw
25. Meter cluster installation
1. Install the meter cluster to the instrument panel.
Note
Connect the switch connector.
1. Clip
26. Side cover installation
1. Install the side cover to the instrument panel.
Note
Install the left and right side covers.
27. Instrument panel assist-side lower cover installation
1. Install the instrument panel assist-side lower cover to
the instrument panel.
Note
Install the 4 screws.
1. Glove box
2. Instrument panel assist side lower cover
28. Glove box installation
1. Install the glove box to the instrument panel.
1. Glove box
2. Instrument panel assist side lower cover
29. Console box installation
Note
Below is for the center console type.
1. Install the console box to the floor.
Heater, Ventilator, Airconditioner (All models) 7B-189
Note
Install the 3 clips.
Open the console box cover and install 2
screws.
Below is for the 2WD center console type.
2. Install the cover to the console box.
Note
Below is for the 4WD center console type.
3. Install the 4WD switch to the console box.
Note
Below is for the center console type.
4. Install the shift console cover to the console box.
Note
Connect the cigarette lighter connector.
Below is for the center console type manual
transmission.
5. Install the shift lever knob to the shift lever.
Note
Below is for the tray type.
Install the console tray to the floor.
Install 2 screws and close the cover.
Below except for the center console type.
6. Install the bracket to the floor.
7. Install the cup holder cover to the bracket.
8. Install the console cover to the instrument panel.
Note
Connect the cigarette lighter connector.
Install the 2 clips.
7B-190 Heater, Ventilator, Airconditioner (All models)
Supplementary Information
1. Component Views Note
Blower motor assembly
1. Instrument panel
2. Instrument panel assist side lower cover
3. Glove box
4. Blower motor assembly
Note
Blower assembly
Heater, Ventilator, Airconditioner (All models) 7B-191
1. Instrument panel
2. Instrument panel driver side lower cover
3. Fuel filler lid opner lever
4. Hood lock control lever
5. Instrument panel assist side lower cover
6. Glove box
7. Blower assembly
Note
Case assembly
7B-192 Heater, Ventilator, Airconditioner (All models)
1. Case assembly
2. Blower unit case assembly
3. Blower motor assembly
4. Blower module assembly
5. Intake actuator
6. Mode lever
Note
Heater evaporator unit assembly
Heater, Ventilator, Airconditioner (All models) 7B-193
1. Instrument panel
2. Instrument panel driver side lower cover
3. Fuel filler lid opner lever
4. Hood lock control lever
5. Heater evaporator unit assembly
6. Glove box
7. Instrument panel assist side lower cover
Note
Vent grille
7B-194 Heater, Ventilator, Airconditioner (All models)
1. Side air outlet grille, left
2. Center ventilation grille, left
3. Center ventilation grille, right
4. Side air outlet grille, right
Note
Defroster nozzle
Heater, Ventilator, Airconditioner (All models) 7B-195
1. Side defroster nozzle, right
2. Ventilation duct, right
3. Ventilation duct, center
4. Ventilation duct, left
5. Side defroster nozzle, left
6. Defroster nozzle
Note
Ventilation duct
7B-196 Heater, Ventilator, Airconditioner (All models)
1. Side defroster nozzle, right
2. Ventilation duct, right
3. Ventilation duct, center
4. Ventilation duct, left
5. Side defroster nozzle, left
6. Defroster nozzle
Note
Control lever assembly
Heater, Ventilator, Airconditioner (All models) 7B-197
1. Instrument panel
2. Bezel bulb
3. Control lever assembly
4. Control panel bezel
5. Instrument panel assist side lower cover
6. Glove box
Note
Blower resister
7B-198 Heater, Ventilator, Airconditioner (All models)
1. Blower assembly 2. Blower resister
Note
Air conditioner compressor assembly
Heater, Ventilator, Airconditioner (All models) 7B-199
1. Compressor
2. Drive belt
3. Compressor bracket
Note
Condenser assembly
7B-200 Heater, Ventilator, Airconditioner (All models)
1. Condenser assembly, integrated with receiver
dryer
Note
Condenser assembly
1. Condenser assembly
2. Refrigerant piping
3. Pressure switch
Note
Electronic thermostat
Heater, Ventilator, Airconditioner (All models) 7B-201
1. Evaporator core
2. Electronic thermostat
3. Heater evaporator unit assembly
4. Heater evaporator unit case
Note
Fin sensor
7B-202 Heater, Ventilator, Airconditioner (All models)
1. Evaporator core
2. Fin sensor
3. Heater evaporator unit assembly
4. Heater evaporator unit case
Note
Fin sensor
Heater, Ventilator, Airconditioner (All models) 7B-203
1. Evaporator core
2. Fin sensor
3. Heater evaporator unit assembly
4. Heater evaporator unit case
Note
Control lever assembly
7B-204 Heater, Ventilator, Airconditioner (All models)
1. Bezel bulb
2. Control lever assembly
3. Control panel bezel
4. Screw
Note
Control lever assembly
1. Air conditioner compressor relay
2. Blower motor relay
3. Air conditioner fuse
Heater, Ventilator, Airconditioner (All models) 7B-205
Note
Control panel assembly, Auto-air conditioner
control unit
1. Control panel assembly, Auto-air conditioner
control unit
2. Instrument panel
Note
Inside air temperature sensor
7B-206 Heater, Ventilator, Airconditioner (All models)
1. Aspirator
2. Aspirator hose
3. Inside air temperature sensor
Note
Outside air temperature sensor
1. Outside air temperature sensor 2. Front bumper assembly
Note
Solar radiation sensor
Heater, Ventilator, Airconditioner (All models) 7B-207
1. Solar radiation sensor
2. Instrument panel
3. Instrument panel upper cover
Note
Intake actuator
7B-208 Heater, Ventilator, Airconditioner (All models)
1. Intake lever
2. Mode lever
3. Intake actuator
4. Blower assembly
1. Mode actuator
Heater, Ventilator, Airconditioner (All models) 7B-209
1. Heater cover
2. Heater evaporator unit assembly
3. Mode actuator
Note
Blower module assembly
7B-210 Heater, Ventilator, Airconditioner (All models)
1. Blower assembly 2. Blower module assembly
2. Tightening Torque Views
Heater, Ventilator, Airconditioner (All models) 7B-211
1 51 Nm { 5.2 kgfm }
2 15 Nm { 1.5 kgfm }
3 6.6 Nm { 0.7 kgfm }
4 15 Nm { 1.5 kgfm }
7B-212 Heater, Ventilator, Airconditioner (All models)
Published: Jul., 2011
First Edition
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
All rights reserved.
0-XXXKI
WORKSHOP MANUAL
HEATING, VENTILATION
AND AIR CONDITIONING
TFHAC-WE-1211TH_67209_|| 2011.7.22 0:46 PM . 1
TFHAC-WE-1211TH_67209_|| 2011.7.22 0:46 PM . 2
WORKSHOP MANUAL
HEATING, VENTILATION
AND AIR CONDITIONING
No.TFHAC-WE-1211TH
2012MY

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