Installation
HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION
1. INSTALL BLOWER ASSEMBLY (w/o PTC Heater)
(a) Install the blower assembly with the 3 screws.
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) Engage each clamp.
3. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY
(a) Engage the 2 claws to install the No. 3 air duct sub-assembly.
4. TEMPORARILY TIGHTEN AIR CONDITIONING UNIT
(a) Engage the drain cooler hose.
(b) 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
(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 9 bolts.
[A] - Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(e) Engage each clamp and the wire harness.
6. 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)
(d) Engage the drain cooler hose.
7. INSTALL HEATER COVER (w/ Cover)
(a) Engage the 4 claws to install the heater cover.
8. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the 2 bolts and the 2 nuts.
(b) Install the instrument panel brace sub-assembly with the 2 screws.
Screw - Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(c) Engage each clamp.
(d) Connect the connector.
(e) Install the 2 bolts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
9. INSTALL THEFT WARNING ECU ASSEMBLY Installation
10. INSTALL CENTER INSTRUMENT PANEL TO COWL BRACE
(a) Install the center instrument panel to cowl brace with the 2 bolts.
11. 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)
12. INSTALL CENTER INSTRUMENT PANEL REGISTER CONNECTOR ASSEMBLY
(a) Engage the 6 claws to install the center instrument panel register connector assembly.
13. INSTALL REAR NO. 1 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 4 claws to install the rear No. 1 air duct.
14. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 2 claws and install the rear No. 2 air duct.
(b) Install the floor carpet and engage the clip.
15. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 2 claws and install the rear No. 3 air duct.
(b) Install the floor carpet and engage the clip.
16. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Installation
17. INSTALL POWER STEERING ECU ASSEMBLY Installation
18. INSTALL STEERING POST ASSEMBLY Installation
19. TURN FRONT WHEELS TO FACE STRAIGHT AHEAD
20. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) Installation
21. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) Installation
22. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation
23. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY Installation
24. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT Installation
25. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
26. INSTALL TRANSPONDER KEY AMPLIFIER (w/ Engine Immobiliser System) Installation
27. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation
28. INSTALL RADIO WIRE SUB-ASSEMBLY Installation
29. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation
30. INSTALL UPPER STEERING COLUMN COVER Installation
31. INSTALL LOWER STEERING COLUMN COVER Installation
32. CONNECT SHIFT LEVER ASSEMBLY (for Manual Transaxle) Installation
33. CONNECT SHIFT LEVER ASSEMBLY (for Automatic Transaxle) Installation
34. INSTALL COWL SIDE TRIM BOARD LH Installation
35. INSTALL FRONT DOOR SCUFF PLATE LH Installation
36. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover) Installation
37. INSTALL COWL SIDE TRIM BOARD RH Installation
38. INSTALL FRONT DOOR SCUFF PLATE RH Installation
39. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation
40. INSTALL NO. 1 SWITCH HOLE BASE Installation
41. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (for Manual Transaxle) Installation
42. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (for Automatic Transaxle) Installation
43. INSTALL FRONT NO. 1 CONSOLE BOX INSERT Installation
44. INSTALL FRONT NO. 2 CONSOLE BOX INSERT Installation
45. INSTALL FRONT CONSOLE BOX ASSEMBLY (for 2WD) Installation
46. INSTALL FRONT CONSOLE BOX ASSEMBLY (for 4WD) Installation
47. INSTALL CONSOLE BOX CARPET
48. INSTALL NO. 2 SWITCH HOLE BASE Installation
49. INSTALL FRONT UPPER CONSOLE BOX Installation
50. INSTALL AIR CONDITIONING PANEL ASSEMBLY Installation
51. INSTALL NAVIGATION ANTENNA CORD SUB-ASSEMBLY (w/ Navigation System) Installation
52. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System) Installation
53. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) Installation
54. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY Installation
55. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation
56. INSTALL NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY Installation
57. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation
58. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle) Installation
59. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle) Installation
60. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Installation
61. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) Installation
62. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY Installation
63. INSTALL FRONT PILLAR GARNISH LH (w/o Curtain Shield Airbag) Installation
64. INSTALL FRONT PILLAR GARNISH LH (w/ Curtain Shield Airbag) Installation
65. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation
66. INSTALL FRONT PILLAR GARNISH RH (w/o Curtain Shield Airbag) Installation
67. INSTALL FRONT PILLAR GARNISH RH (w/ Curtain Shield Airbag) Installation
68. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation
69. INSTALL COMBINATION METER ASSEMBLY Installation
70. INSTALL METER HOOD SUB-ASSEMBLY Installation
71. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation
72. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation
73. TURN FRONT WHEELS TO FACE STRAIGHT AHEAD
74. ADJUST SPIRAL CABLE Installation
75. INSTALL STEERING WHEEL ASSEMBLY Installation
76. INSTALL STEERING PAD Installation
77. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation
78. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation
79. INSPECT STEERING WHEEL CENTER POINT
80. INSTALL HEATER OUTLET WATER HOSE
(a) Install the water hose and attach the clip.
81. INSTALL HEATER INLET WATER HOSE
(a) Use the same procedure described for the heater outlet water hose.
82. INSTALL LIQUID PIPE SUB-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 liquid pipe sub-assembly.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the liquid pipe sub-assembly.
(d) Install the liquid pipe sub-assembly.
83. 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)
84. CHARGE WITH REFRIGERANT Service and Repair
85. ADD ENGINE COOLANT (for 2AZ-FE) Service and Repair
86. ADD ENGINE COOLANT (for 2ZR-FE) Service and Repair
87. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
88. INSPECT FOR COOLANT LEAK (for 2AZ-FE) Testing and Inspection
89. INSPECT FOR COOLANT LEAK (for 2ZR-FE) Testing and Inspection
90. INSPECT STEERING PAD Installation
91. INSPECT SRS WARNING LIGHT
Diagnosis System
92. WARM UP ENGINE Service and Repair
93. INSPECT FOR REFRIGERANT LEAK Service and Repair