Diesel Data: Automotive Repair
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Installation








HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION

INSTALLATION

1. INSTALL AIR CONDITIONING UNIT ASSEMBLY
(a) Install the air conditioning unit assembly with the 3 nuts.





Torque: 9.8 Nm (100 kgf-cm, 87in-lbf)
NOTICE: Tighten the nuts in the order shown in the illustration to install the air conditioning unit assembly.

2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY
(a) Driver Side:
(1) Using a "TORX" socket wrench (T40), install the 2 "TORX" bolts.
Torque: 19 Nm (194 kgf-cm, 15ft-lbf)
(2) Install the bolt.
Torque: 19 Nm (194 kgf-cm, 15ft-lbf)
(b) Passenger Side:
(1) Using a 12 mm hexagon wrench, install the 2 collars for adjustment.
Torque: 6.0 Nm (61 kgf-cm, 53in-lbf)
(2) Using a "TORX" socket wrench (T40), install the 2 "TORX" bolts.
Torque: 19 Nm (194 kgf-cm, 15ft-lbf)





Text in Illustration





(c) for LH side:




(1) Install the hole plug.
(d) for RH side:




(1) Install the hole plug.
(e) Install the 2 bolts to the engine compartment side.
Torque: 17 Nm (175 kgf-cm, 13ft-lbf)
(f) Install the instrument panel reinforcement assembly with air conditioning unit assembly with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87in-lbf)
(g) Connect the cooler drain hose.





Text in Illustration





(h) Install the bolt.
Torque: 19 Nm (194 kgf-cm, 15ft-lbf)
(i) Install the 2 nuts and screw.
(j) Engage each clamp.
(k) Connect the blower motor connector.
(l) Connect each connector.





Text in Illustration





3. 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.
(c) Connect the earth wire with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74in-lbf)
(d) Engage each clamp.

Text in Illustration





4. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY





(a) Install the screw.
(b) Install the No. 1 instrument panel brace sub-assembly with the 2 bolts and 2 nuts.
(c) Connect the earth wire with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74in-lbf)

Text in Illustration









(d) Engage each clamp.
5. INSTALL NO. 3 INSTRUMENT PANEL REINFORCEMENT





(a) Install the No. 3 instrument panel reinforcement with the 2 nuts.
(b) Connect the earth wire with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74in-lbf)
(c) Engage the clamp.

Text in Illustration





6. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY





(a) Engage the 4 claws to install the No. 6 heater to register duct assembly.
(b) Engage the clamp.
7. INSTALL NO. 1 CONSOLE BOX DUCT





(a) Install the No. 1 console box duct with the clip as shown in the illustration.
8. INSTALL FLOOR CARPET BRACKET LH





(a) Install the floor carpet bracket LH with the 3 clips.
(b) Engage each clamp.
9. INSTALL REAR NO. 1 AIR DUCT





(a) Engage the 2 claws to install the rear No. 1 air duct.
10. INSTALL REAR NO. 2 AIR DUCT





(a) Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.
11. INSTALL FLOOR CARPET BRACKET RH





(a) Install the floor carpet bracket RH with the 3 clips.
12. INSTALL REAR NO. 3 AIR DUCT





(a) Engage the 2 claws to install the rear No. 3 air duct.
13. INSTALL REAR NO. 4 AIR DUCT





(a) Engage the 4 claws to install the rear No. 4 air duct as shown in the illustration.
14. INSTALL POWER STEERING ECU ASSEMBLY Installation
15. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY Installation
16. INSTALL TIRE PRESSURE WARNING ECU Installation
17. INSTALL 4WD CONTROL ECU (for AWD)
18. INSTALL POWER MANAGEMENT CONTROL ECU Installation
19. INSTALL TURN SIGNAL FLASHER ASSEMBLY Installation
20. INSTALL STEERING POST ASSEMBLY Installation
21. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
22. INSTALL FRONT WHEEL LH Installation
23. INSTALL TRANSPONDER KEY AMPLIFIER (w/o Smart Key System) Installation
24. INSTALL INSTRUMENT PANEL STAY Installation
25. INSTALL INSTRUMENT PANEL CLIP Installation
26. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Installation
27. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation
28. INSTALL SHIFT LEVER ASSEMBLY
for U660F:
for U660E:
29. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY Installation
30. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH (for 6 Speakers) Installation
31. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH (for 13 Speakers) Installation
32. INSTALL FRONT PILLAR GARNISH RH
HINT: Use the same procedure for the RH side and LH side.

33. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation
34. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)
HINT: Use the same procedure for the RH side and LH side.

35. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation
36. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY Installation
37. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (for 6 Speakers) Installation
38. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (for 13 Speakers) Installation
39. INSTALL FRONT PILLAR GARNISH LH Installation
40. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation
41. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) Installation
42. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation
43. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System) Installation
44. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System) Installation
45. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System) Installation
46. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System) Installation
47. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY (for 13 Speakers) Installation
48. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation
49. INSTALL CONSOLE BOX SUB-ASSEMBLY Installation
50. INSTALL POSITION INDICATOR HOUSING ASSEMBLY Installation
51. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Installation
52. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation
53. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
54. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH
HINT: Use the same procedure for the RH side and LH side.

55. INSTALL FRONT DOOR SCUFF PLATE RH
HINT: Use the same procedure for the RH side and LH side.

56. INSTALL LOWER NO. 1 INSTRUMENT PANEL FINISH PANEL Installation
57. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation
58. INSTALL FRONT DOOR SCUFF PLATE LH Installation
59. INSTALL AIR CONDITIONING CONTROL ASSEMBLY Installation
60. INSTALL CONSOLE BOX ASSEMBLY Installation
61. INSTALL NO. 2 CONSOLE BOX CARPET Installation
62. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (w/o Seat Heater System) Installation
63. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (w/ Seat Heater System) Installation
64. INSTALL ACCESSORY METER ASSEMBLY (w/o Rear View Monitor System) Installation
65. INSTALL ACCESSORY METER ASSEMBLY (w/ Rear View Monitor System) Installation
66. INSTALL DEFROSTER NOZZLE GARNISH Installation
67. INSTALL COMBINATION METER ASSEMBLY Installation
68. INSTALL INSTRUMENT CLUSTER FINISH PANEL Installation
69. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation
70. INSTALL UPPER STEERING COLUMN COVER Installation
71. INSTALL LOWER STEERING COLUMN COVER Installation
72. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
73. ADJUST SPIRAL CABLE Installation
74. INSTALL STEERING WHEEL ASSEMBLY Installation
75. INSTALL STEERING PAD Installation
76. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation
77. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation
78. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
(a) Remove the attached vinyl tape from the pipe.
(b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube and accessory assembly.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the air conditioning tube and accessory assembly.
NOTICE: Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

(d) Install the air conditioning tube and accessory assembly.
79. CONNECT SUCTION HOSE SUB-ASSEMBLY
(a) Remove the attached 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 8 or equivalent
(c) Install the O-ring on the suction hose sub-assembly.
NOTICE: Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.

(d) Install 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, 87in-lbf)
80. CONNECT INLET HEATER WATER HOSE





(a) Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.
81. CONNECT OUTLET HEATER WATER HOSE





(a) Using pliers, grip the claws of the clip and slide the clip to connect the outlet heater water hose.
82. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
83. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
84. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
85. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation
86. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation
87. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
88. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
89. INSTALL FRONT WIPER ARM HEAD CAP Installation
90. INSTALL FRONT SEAT ASSEMBLY LH (for Manual Seat) Installation
91. INSPECT FRONT SEAT SLIDE ADJUSTER LOCK Installation
92. INSTALL FRONT SEAT REAR INNER TRACK COVER LH (for Manual Seat) Installation
93. INSTALL FRONT SEAT REAR OUTER TRACK COVER LH (for Manual Seat) Installation
94. INSTALL FRONT SEAT ASSEMBLY RH (for Manual Seat)
HINT: Use the same procedure for the RH side and LH side.

95. INSPECT FRONT SEAT SLIDE ADJUSTER LOCK Installation
96. INSTALL FRONT SEAT REAR INNER TRACK COVER RH (for Manual Seat)
HINT: Use the same procedure for the RH side and LH side.

97. INSTALL FRONT SEAT REAR OUTER TRACK COVER RH (for Manual Seat)
HINT: Use the same procedure for the RH side and LH side.

98. INSTALL FRONT SEAT ASSEMBLY LH (for Power Seat) Installation
99. INSTALL FRONT SEAT REAR INNER TRACK COVER LH (for Power Seat) Installation
100. INSTALL FRONT SEAT REAR OUTER TRACK COVER LH (for Power Seat) Installation
101. INSTALL FRONT SEAT ASSEMBLY RH (for Power Seat)
HINT: Use the same procedure for the RH side and LH side.

102. INSTALL FRONT SEAT REAR INNER TRACK COVER RH (for Power Seat)
HINT: Use the same procedure for the RH side and LH side.

103. INSTALL FRONT SEAT REAR OUTER TRACK COVER LH (for Power Seat)
HINT: Use the same procedure for the RH side and LH side.

104. INSTALL FRONT SEAT HEADREST ASSEMBLY Installation
105. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

106. ADD ENGINE COOLANT Service and Repair
107. INSPECT FOR COOLANT LEAK Testing and Inspection
108. CHARGE WITH REFRIGERANT Service and Repair
109. WARM UP ENGINE Service and Repair
110. INSPECT FOR REFRIGERANT LEAK Service and Repair
111. INSPECT STEERING PAD Installation
112. INSPECT FRONT SEAT ASSEMBLY (for Power Seat) Installation
113. INSPECT SRS WARNING LIGHT Diagnosis System
114. INSPECT SEAT BELT WARNING SYSTEM On-Vehicle Inspection
115. INSPECT SHIFT LEVER POSITION
for U660F:
for U660E:
116. ADJUST SHIFT LEVER POSITION
for U660F:
for U660E:
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