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 CENTER INSTRUMENT PANEL TO COWL BRACE
(a) Install the center instrument panel to cowl brace with the 2 bolts.
10. 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)
11. INSTALL CENTER INSTRUMENT PANEL REGISTER CONNECTOR ASSEMBLY
(a) Engage the 6 claws to install the center instrument panel register connector assembly.
12. INSTALL REAR NO. 1 AIR DUCT (w/ Rear Air Duct)
(a) Engage the 4 claws to install the rear No. 1 air duct.
13. 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.
14. 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.
15. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Installation
16. INSTALL POWER STEERING ECU ASSEMBLY Installation
17. INSTALL STEERING POST ASSEMBLY Installation
18. TURN FRONT WHEELS TO FACE STRAIGHT AHEAD
19. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) Installation
20. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) Installation
21. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation
22. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY Installation
23. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT Installation
24. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
25. INSTALL TRANSPONDER KEY AMPLIFIER (w/ Engine Immobiliser System) Installation
26. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation
27. INSTALL RADIO WIRE SUB-ASSEMBLY Installation
28. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation
29. INSTALL UPPER STEERING COLUMN COVER Installation
30. INSTALL LOWER STEERING COLUMN COVER Installation
31. CONNECT SHIFT LEVER ASSEMBLY (for Manual Transaxle) Installation
32. CONNECT SHIFT LEVER ASSEMBLY (for Automatic Transaxle) Installation
33. INSTALL COWL SIDE TRIM BOARD LH Installation
34. INSTALL FRONT DOOR SCUFF PLATE LH Installation
35. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Instrument Panel Under Cover) Installation
36. INSTALL COWL SIDE TRIM BOARD RH Installation
37. INSTALL FRONT DOOR SCUFF PLATE RH Installation
38. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation
39. INSTALL NO. 1 SWITCH HOLE BASE Installation
40. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (for Manual Transaxle) Installation
41. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (for Automatic Transaxle) Installation
42. INSTALL FRONT NO. 1 CONSOLE BOX INSERT Installation
43. INSTALL FRONT NO. 2 CONSOLE BOX INSERT Installation
44. INSTALL FRONT CONSOLE BOX ASSEMBLY (for 2WD) Installation
45. INSTALL FRONT CONSOLE BOX ASSEMBLY (for 4WD) Installation
46. INSTALL CONSOLE BOX CARPET
47. INSTALL NO. 2 SWITCH HOLE BASE Installation
48. INSTALL FRONT UPPER CONSOLE BOX Installation
49. INSTALL AIR CONDITIONING PANEL ASSEMBLY Installation
50. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET Installation
51. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY Installation
52. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation
53. INSTALL NO. 1 INSTRUMENT PANEL BOX DOOR SUB-ASSEMBLY Installation
54. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation
55. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Manual Transaxle) Installation
56. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (for Automatic Transaxle) Installation
57. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Installation
58. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transaxle) Installation
59. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY Installation
60. INSTALL FRONT PILLAR GARNISH LH Installation
61. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation
62. INSTALL FRONT PILLAR GARNISH RH Installation
63. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation
64. INSTALL COMBINATION METER ASSEMBLY Installation
65. INSTALL METER HOOD SUB-ASSEMBLY Installation
66. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation
67. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY Installation
68. TURN FRONT WHEELS TO FACE STRAIGHT AHEAD
69. ADJUST SPIRAL CABLE Installation
70. INSTALL STEERING WHEEL ASSEMBLY
Installation
71. INSPECT STEERING WHEEL CENTER POINT
72. INSTALL HEATER OUTLET WATER HOSE
(a) Install the water hose and attach the clip.
73. INSTALL HEATER INLET WATER HOSE
(a) Use the same procedure described for the heater outlet water hose.
74. 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.
75. 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)
76. CHARGE WITH REFRIGERANT Service and Repair
77. ADD ENGINE COOLANT (for 2AZ-FE) Service and Repair
78. ADD ENGINE COOLANT (for 2ZR-FE) Service and Repair
79. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
80. INSPECT FOR COOLANT LEAK (for 2AZ-FE) Testing and Inspection
81. INSPECT FOR COOLANT LEAK (for 2ZR-FE) Testing and Inspection
82. INSPECT STEERING PAD Installation
83. INSPECT SRS WARNING LIGHT
Diagnosis System
84. WARM UP ENGINE Service and Repair
85. INSPECT FOR REFRIGERANT LEAK Service and Repair