Installation
HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION
INSTALLATION
1. INSTALL BLOWER ASSEMBLY (w/o PTC Heater)
(a) Install the blower assembly with the 3 screws.
(b) for Automatic Air Conditioning System:
(1) Connect the connector.
2. INSTALL BLOWER ASSEMBLY (w/ PTC Heater)
(a) Install the blower assembly with the 3 screws.
(b) Engage the quick heater connector and install the screw.
(c) for Automatic Air Conditioning System:
(1) Connect the connector.
(d) Engage each clamp.
3. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY
(a) Engage the 2 claws and install the No. 2 air duct sub-assembly.
4. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT
(a) Temporarily tighten the air conditioning unit with the bolt and the nut.
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.
5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Manual Air Conditioning System)
(a) Install the instrument panel reinforcement assembly with the 7 bolts.
[A] - Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
(b) Connect each connector.
(c) Engage each clamp.
(d) Engage the wire harness and junction block with the 12 bolts.
[A] - Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(e) Engage the cooler drain hose.
(f) Engage each clamp and the wire harness.
6. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (for Automatic Air Conditioning System)
(a) Install the instrument panel reinforcement assembly with the 7 bolts.
[A] - Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
(b) Connect each connector.
(c) Engage each clamp.
(d) Engage the wire harness and junction block with the 12 bolts.
[A] - Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)
(e) Engage the cooler drain hose.
(f) Engage each clamp and the wire harness.
7. INSTALL AIR CONDITIONING UNIT
(a) Install the 3 bolts.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
HINT: Tighten the bolts in the order shown in the illustration.
(b) Install the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
(c) Install the air conditioning unit with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
8. INSTALL HEATER COVER (w/ Cover)
(a) Engage the 4 claws and install the heater cover.
9. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 4 claws and install the rear No. 1 air duct.
10. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the No. 2 instrument panel brace sub-assembly with the bolt, screw and the nut.
Screw - Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) for TMC Made:
(1) Engage the clamp.
(c) for TMMC, NUMMI Made:
(1) Engage each clamp.
11. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Manual Air Conditioning System)
(a) Install the No. 1 instrument panel brace sub-assembly with the bolt, screw and the nut.
Screw - Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) for TMC Made:
(1) Engage each clamp.
(2) Connect the connector.
(c) for TMMC, NUMMI Made:
(1) Engage each clamp.
(2) Connect the connector.
12. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (for Automatic Air Conditioning System)
(a) Install the No. 1 instrument panel brace sub-assembly with the bolt, screw and the nut.
Screw - Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) for TMC Made:
(1) Engage each clamp.
(c) for TMMC, NUMMI Made:
(1) Engage each clamp.
13. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 2 claws to install the rear No. 3 air duct.
(b) Engage the clip and install the floor carpet.
14. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 2 claws to install the rear No. 2 air duct.
(b) Engage the clip and install the floor carpet.
15. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE
(a) Install the center instrument panel to cowl brace with the 2 bolts.
16. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Engage the 6 claws and install the lower defroster nozzle assembly.
17. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY
(a) Install the No. 1 air duct sub-assembly with the 2 nuts.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
18. INSTALL SMART KEY ECU ASSEMBLY (w/ Smart Key System) Installation
19. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation
20. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY Installation
21. INSTALL CONSOLE BOX ASSEMBLY (for Manual Transaxle) Installation
22. INSTALL CONSOLE BOX ASSEMBLY (for Automatic Transaxle) Installation
23. INSTALL CONSOLE BOX CARPET Installation
24. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY Installation
25. INSTALL NO. 1 SWITCH HOLE BASE (w/o Smart Key System) Installation
26. INSTALL NO. 1 SWITCH HOLE BASE (w/ Smart Key System) Installation
27. INSTALL FRONT NO. 1 CONSOLE BOX INSERT Installation
28. INSTALL COWL SIDE TRIM BOARD LH Installation
29. INSTALL FRONT DOOR SCUFF PLATE LH Installation
30. INSTALL FRONT NO. 2 CONSOLE BOX INSERT Installation
31. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover) Installation
32. INSTALL COWL SIDE TRIM BOARD RH Installation
33. INSTALL FRONT DOOR SCUFF PLATE RH Installation
34. INSTALL AIR CONDITIONING PANEL ASSEMBLY (for Manual Air Conditioning System) Installation
35. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System) Installation
36. INSTALL INSTRUMENT PANEL HOLE COVER Installation
37. INSTALL INSTRUMENT PANEL BOX ASSEMBLY Installation
38. INSTALL CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle) Installation
39. INSTALL CENTER NO. 1 INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle) Installation
40. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Installation
41. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) Installation
42. INSTALL RADIO RECEIVER WITH BRACKET (w/o Navigation System) Installation
43. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (w/ Navigation System) Installation
44. INSTALL NAVIGATION RECEIVER WITH BRACKET (w/ Navigation System) Installation
45. INSTALL STEERING POST ASSEMBLY (for 2ZR-FE) Installation
46. INSTALL STEERING POST ASSEMBLY (for 2AZ-FE) Installation
47. TURN FRONT WHEELS FACING STRAIGHT AHEAD
48. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
49. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation
50. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY Installation
51. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT Installation
52. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
53. INSTALL TRANSPONDER KEY AMPLIFIER (w/o Smart Key System) Installation
54. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation
55. INSTALL UPPER STEERING COLUMN COVER Installation
56. INSTALL LOWER STEERING COLUMN COVER Installation
57. TURN FRONT WHEELS FACING STRAIGHT AHEAD
58. ADJUST SPIRAL CABLE Installation
59. INSTALL STEERING WHEEL ASSEMBLY Installation
60. INSTALL STEERING PAD Installation
61. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation
62. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation
63. INSPECT STEERING WHEEL CENTER POINT
64. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation
65. INSTALL POWER STEERING ECU ASSEMBLY (for 2ZR-FE) Installation
66. INSTALL POWER STEERING ECU ASSEMBLY (for 2AZ-FE) Installation
67. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY Installation
68. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation
69. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation
70. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY Installation
71. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation
72. INSTALL NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY Installation
73. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation
74. INSTALL FRONT PILLAR GARNISH LH (w/ Curtain Shield Airbag) Installation
75. INSTALL FRONT PILLAR GARNISH LH (w/o Curtain Shield Airbag) Installation
76. INSTALL FRONT PILLAR GARNISH RH (w/ Curtain Shield Airbag) Installation
77. INSTALL FRONT PILLAR GARNISH RH (w/o Curtain Shield Airbag) Installation
78. INSTALL COMBINATION METER ASSEMBLY Installation
79. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY Installation
80. INSTALL CENTER INSTRUMENT PANEL REGISTER ASSEMBLY Installation
81. INSTALL INSTRUMENT PANEL FINISH PANEL END LH Installation
82. INSTALL INSTRUMENT PANEL FINISH PANEL END RH Installation
83. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH Installation
84. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL RH Installation
85. INSTALL HEATER OUTLET WATER HOSE
(a) Install the water hose and attach the clip.
86. INSTALL HEATER INLET WATER HOSE
HINT: Use the same procedure described for the heater outlet water hose.
87. INSTALL AIR CONDITIONING TUBE ASSEMBLY
(a) Remove the attached vinyl tape from the tube.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assembly.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the air conditioning tube assembly.
(d) Install the air conditioning tube assembly.
88. INSTALL SUCTION PIPE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the hose.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the suction hose sub-assembly.
(d) Move the hook connector in the direction indicated by the arrow in the illustration.
(e) Insert the pipe joint into the fitting hole securely and tighten the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
89. INSTALL OUTER COWL TOP PANEL (for TMC Made) Installation
90. INSTALL OUTER COWL TOP PANEL (except TMC Made) Installation
91. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
92. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
93. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER Installation
94. INSTALL HOOD TO COWL TOP SEAL Installation
95. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
96. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
97. INSTALL FRONT WIPER ARM HEAD CAP Installation
98. CHARGE WITH REFRIGERANT Service and Repair
99. ADD ENGINE COOLANT (for 2ZR-FE) Service and Repair
100. ADD ENGINE COOLANT (for 2AZ-FE) Service and Repair
101. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
102. INSPECT FOR COOLANT LEAK (for 2ZR-FE) Testing and Inspection
103. INSPECT FOR COOLANT LEAK (for 2AZ-FE) Testing and Inspection
104. INSPECT STEERING PAD Installation
105. INSPECT SRS WARNING LIGHT
Diagnosis System
106. WARM UP ENGINE Service and Repair
107. INSPECT FOR REFRIGERANT LEAK Service and Repair