Installation
HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION
1. INSTALL AIR CONDITIONING UNIT ASSEMBLY
(a) Install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to install the air conditioning unit assembly.
2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT
NOTICE:
* Be sure to support the air conditioning unit assembly when removing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
* When installing the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
(a) Disengage the 3 guides and temporarily install the instrument panel reinforcement assembly with air conditioning unit as shown in the illustration.
(b) Install the instrument panel reinforcement assembly with the 3 bolts and 2 new bolts in the order shown in the illustration.
Text in Illustration
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration to install the reinforcement assembly.
(c) Install the instrument panel reinforcement assembly with air conditioning unit with the nut.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(d) Install the bolt.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
(e) Install the 2 bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTICE:
Tighten the bolts in the order shown in the illustration.
(f) Install the instrument panel reinforcement assembly with air conditioning unit with the nut.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(g) Install the 2 bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(h) Engage each clamp.
(i) Connect the connector.
(j) Install the 2 nuts and connect the connector holder.
(k) Install the bolt and connect the earth wire.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(l) Engage each clamp.
(m) Connect the connector.
(n) Install the 2 bolts and connect the 2 earth wires.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(o) Engage each clamp.
(p) Pass the drain cooler hose through the vehicle securely.
NOTICE:
Connect the drain cooler hose firmly to prevent water leaks.
(q) Engage each clamp.
(r) Connect the connector.
(s) Engage each clamp.
(t) Engage the claw to connect the airbag connector as shown in the illustration.
(u) Engage the 2 claws to lock the retainer as shown in the illustration.
Text in Illustration
(v) Connect the connector.
(w) Install the bolt.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
(x) Install the shift lever support with the 4 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(y) Check that the park/neutral position switch and the shift lever are in N.
(z) Install the lower shift lever assembly with the 4 bolts in the order shown in the illustration.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(aa) Slide the slider of the transmission control cable assembly in the direction indicated by the arrow and pull the lock piece outward.
Text in Illustration
(ab) Install the end of the transmission control cable assembly to the lower shift lever assembly.
Text in Illustration
NOTICE:
* Check that the lock piece is pulled up.
* Install the cable end all the way to the base of the pin.
(ac) Push the lock piece into the adjuster case.
NOTICE:
* Check that the park/neutral position switch and the shift lever are in neutral.
* Securely push in the lock piece until the slider lock is engaged.
(ad) Connect each connector.
Text in Illustration
(ae) Engage the 3 clamps.
(af) Connect the center airbag sensor connectors to the center airbag sensor assembly as shown in the illustration.
NOTICE:
When connecting any airbag connector, take care not to damage the airbag wire harness.
(ag) Engage the 3 claws to close the 3 clamps as shown in the illustration.
3. INSTALL FRONT LOWER PANEL PACKING
(a) Install the 2 front lower panel packings shown in the illustration.
4. INSTALL INSTRUMENT PANEL SAFETY PAD CAP
(a) Install 5 new instrument panel safety pad caps.
Text in Illustration
5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the screw.
(b) Install the No. 2 instrument panel brace sub-assembly with the bolt and 2 nuts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(c) Connect the earth wire with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(d) Engage each clamp.
(e) Connect the connector.
6. INSTALL INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY
(a) Install the screw.
(b) Install the instrument panel to cowl brace sub-assembly with the bolt and 2 nuts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(c) Connect the earth wire with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(d) Engage each clamp.
(e) Connect each connector.
7. INSTALL NO. 1 CONSOLE BOX DUCT (w/ Rear Register Duct)
(a) Install the No. 1 console box duct with the clip.
8. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET
(a) Install the No. 1 console mounting bracket with the screw.
9. INSTALL REAR NO. 3 AIR DUCT
(a) Engage the 2 claws to install the rear No. 3 air duct.
10. INSTALL FLOOR CARPET BRACKET LH
(a) Engage the 2 guides.
(b) Install the floor carpet bracket LH with the 2 clips.
11. INSTALL REAR NO. 4 AIR DUCT
(a) Engage the 4 claws to install the rear No. 4 air duct as shown in the illustration.
(b) Engage the guide to install the floor carpet to the original position as shown in the illustration.
12. CONNECT FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY
(a) Engage the guide to connect the fuel lid lock open lever sub-assembly as shown in the illustration.
(b) Install the screw.
13. INSTALL REAR NO. 1 AIR DUCT
(a) Engage the 2 claws to install the rear No. 1 air duct.
14. INSTALL FLOOR CARPET BRACKET RH
(a) Engage the 2 guides.
(b) Install the floor carpet bracket RH with the 2 clips.
15. INSTALL REAR NO. 2 AIR DUCT
(a) Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.
(b) Engage the guide to install the floor carpet to the original position as shown in the illustration.
16. INSTALL FLOOR CARPET HOOK
(a) Engage the 6 claws to install the 6 floor carpet hooks.
(b) Engage the 6 guides.
17. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Installation
18. INSTALL ECU INTEGRATION BOX RH Installation
19. INSTALL VEHICLE APPROACHING SPEAKER CONTROLLER Installation
20. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY Installation
21. INSTALL POWER MANAGEMENT CONTROL ECU Installation
22. INSTALL STEERING POST ASSEMBLY
Installation
23. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY
Installation
24. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY WITH BRACKET (for 10 Speakers) Installation
25. INSTALL AUDIO AMPLIFIER COVER (for 10 Speakers) Installation
26. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat)
Installation
27. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat)
Installation
28. INSTALL DCM (TELEMATICS TRANSCEIVER) WITH BACK-UP BATTERY (w/ Manual (SOS) Switch) Installation
29. INSTALL AUDIO AMPLIFIER COVER (w/ Manual (SOS) Switch) Installation
30. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT
Use the same procedure for the RH side and LH side.
31. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT
Use the same procedure for the RH side and LH side.
32. CONNECT AIR CONDITIONER TUBE AND ACCESSORY ASSEMBLY
(a) Remove the vinyl tape from the pipe.
(b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioner tube and accessory assembly.
Compressor oil:
ND-OIL 11 or equivalent
(c) Install the O-ring to the air conditioner tube and accessory assembly.
(d) Install the air conditioner tube and accessory assembly.
33. CONNECT SUCTION HOSE SUB-ASSEMBLY
(a) Remove the vinyl tape from the pipe.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.
Compressor oil:
ND-OIL 11 or equivalent
(c) Connect the O-ring to the suction hose sub-assembly.
(d) Connect the suction hose sub-assembly.
(e) Move the hook connector in the direction indicated by the arrow in the illustration.
(f) Insert the pipe joint into the fitting hole securely and tighten the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
34. CONNECT HEATER INLET WATER HOSE
(a) Install the heater inlet water hose and attach the clip.
35. CONNECT HEATER OUTLET WATER HOSE
(a) Install the heater outlet water hose and attach the clip.
36. INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
37. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Installation
38. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection
39. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine) Testing and Inspection
40. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT Service and Repair
41. WARM UP COMPRESSOR Service and Repair
42. INSPECT FOR REFRIGERANT LEAK Service and Repair
43. INITIALIZATION SERVO MOTOR
Initialization