Up to 08/2009
HEATING / AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION
1. INSTALL AIR CONDITIONING UNIT ASSEMBLY
(a) Install the air conditioning unit assembly with the 3 bolts in the order shown in the illustration.
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 NO. 1 AIR DUCT SUB-ASSEMBLY
(a) Engage the 4 claws to install the No. 1 air duct sub-assembly.
3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY
(a) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 5 "TORX" bolts in the order shown in the 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.
(b) Install the 5 instrument panel safety pad caps.
Text in Illustration
(c) Install the 2 bolts and 2 caps to engine compartment side.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(d) Install the instrument panel reinforcement assembly with air conditioning unit assembly with the nut.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(e) Connect the cooler drain hose as shown in the illustration.
NOTICE:
Connect the cooler drain hose firmly to prevent water leaks.
Text in Illustration
(f) Engage each clamp.
(g) Install the bolt and connect the earth wire.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(h) Connect the connector holder with the nut.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(i) Connect the connector.
(j) Connect the blower motor connector.
(k) Connect the 2 air conditioning ECU connectors.
Text in Illustration
(l) Engage each clamp.
(m) Connect the earth wire with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(n) Connect each connector.
Text in Illustration
4. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the 2 bolts and 2 nuts.
Bolt - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
Nut - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(b) Install the No. 2 instrument panel brace sub-assembly with the screw.
(c) Engage each clamp.
Text in Illustration
5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the 2 bolts and 2 nuts.
Bolt - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
Nut - Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(b) Install the No. 1 instrument panel brace sub-assembly with the screw.
(c) Engage each clamp.
Text in Illustration
6. INSTALL NO. 5 INSTRUMENT PANEL BRACKET (w/o Navigation System for HDD)
(a) Install the 2 No. 5 instrument panel brackets.
7. INSTALL CENTER HEATER TO REGISTER SUB DUCT
(a) Install the center heater to register sub duct with the 3 clips.
8. INSTALL REAR NO. 3 AIR DUCT
(a) Engage the 2 claws to install the rear No. 3 air duct.
9. INSTALL REAR NO. 4 AIR DUCT
(a) Engage the claw to install the rear No. 4 air duct.
(b) Install the clip.
(c) Engage the claw and 2 clamps.
(d) Engage the fastener to install the floor carpet to the original position.
Text in Illustration
10. INSTALL FRONT FLOOR CAUTION PLATE COVER
(a) Engage the guide as shown in the illustration.
(b) Engage the claw to install the frame number cover.
11. INSTALL REAR NO. 1 AIR DUCT
(a) Engage the 2 claws to install the rear No. 1 air duct.
(b) Engage the clamp.
12. INSTALL REAR NO. 2 AIR DUCT
(a) Engage the claw to install the rear No. 2 air duct.
(b) Install the clip.
(c) Engage the claw and 2 clamps.
(d) Engage the fastener to install the floor carpet to the original position.
Text in Illustration
13. INSTALL ECU INTEGRATION BOX Installation
14. INSTALL DISPLAY AND NAVIGATION MODULE DISPLAY WITH BRACKET (w/ Navigation System for HDD) Installation
15. INSTALL CLEARANCE WARNING BUZZER Installation
16. INSTALL TURN SIGNAL FLASHER ASSEMBLY Installation
17. INSTALL POWER STEERING ECU ASSEMBLY Installation
18. INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY Installation
19. INSTALL NO. 3 INSTRUMENT PANEL STAY Installation
20. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY Installation
21. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation
22. INSTALL NO. 1 CONSOLE BOX DUCT Installation
23. INSTALL SHIFT LEVER ASSEMBLY Installation
24. INSTALL NO. 1 DEFROSTER NOZZLE GARNISH Installation
25. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY Installation
26. INSTALL NO. 1 SPEAKER OPENING COVER ASSEMBLY Installation
27. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY Installation
28. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY Installation
29. INSTALL FRONT PILLAR GARNISH LH Installation
30. INSTALL INSTRUMENT SIDE PANEL LH Installation
31. INSTALL FRONT PILLAR GARNISH RH Installation
32. INSTALL INSTRUMENT SIDE PANEL RH Installation
33. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation
34. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY Installation
35. INSTALL INSTRUMENT PANEL GARNISH RH Installation
36. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
37. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH Installation
38. INSTALL FRONT DOOR SCUFF PLATE RH Installation
39. INSTALL CONSOLE BOX Installation
40. INSTALL RADIO RECEIVER ASSEMBLY WITH REGISTER Installation
41. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL Installation
42. INSTALL INSTRUMENT PANEL FINISH PANEL Installation
43. INSTALL MULTI-DISPLAY ASSEMBLY (w/ Navigation System) Installation
44. INSTALL ACCESSORY METER ASSEMBLY (w/o Navigation System) Installation
45. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL Installation
46. INSTALL COMBINATION METER ASSEMBLY Installation
47. INSTALL NO. 1 INSTRUMENT CLUSTER FINISH PANEL Installation
48. INSTALL NO. 1 INSTRUMENT PANEL HOLE COVER Installation
49. INSTALL NO. 2 INSTRUMENT PANEL HOLE COVER Installation
50. INSTALL STEERING POST ASSEMBLY Installation
51. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
52. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY Installation
53. CONNECT MASTER CYLINDER PUSH ROD CLEVIS Installation
54. INSTALL BRAKE PEDAL RETURN SPRING Installation
55. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY Installation
56. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation
57. INSPECT AND ADJUST BRAKE PEDAL
HINT
Adjustments
58. INSTALL NO. 4 AIR DUCT SUB-ASSEMBLY Installation
59. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY Installation
60. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation
61. INSTALL NO. 1 SWITCH HOLE BASE Installation
62. INSTALL INSTRUMENT PANEL GARNISH LH Installation
63. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
64. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation
65. INSTALL FRONT DOOR SCUFF PLATE LH Installation
66. INSTALL REAR CONSOLE BOX ASSEMBLY Installation
67. INSTALL MULTI-MEDIA INTERFACE ECU ASSEMBLY (w/ USB Audio System) Installation
68. INSTALL CONSOLE REAR END PANEL SUB-ASSEMBLY Installation
69. INSTALL NO. 2 CONSOLE BOX DUCT Installation
70. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY Installation
71. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Installation
72. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation
73. INSTALL STEERING COLUMN COVER Installation
74. ADJUST SPIRAL CABLE Installation
75. INSTALL STEERING WHEEL ASSEMBLY Installation
76. INSPECT STEERING WHEEL CENTER POINT
77. INSTALL STEERING PAD Installation
78. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation
79. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation
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. 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 the fitting surface of the air conditioning tube and accessory assembly.
Compressor oil:
ND-OIL 11 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 clean from dirt or any foreign objects.
* Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
(d) Install the air conditioning tube and accessory assembly.
83. CONNECT SUCTION PIPE 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 pipe sub-assembly.
Compressor oil:
ND-OIL 11 or equivalent
(c) Install the O-ring on the suction pipe sub-assembly.
NOTICE:
* Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.
* Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
(d) Install the suction pipe 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)
(g) Engage the 6 clamps to the engine wire harness.
84. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
85. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension) Installation
86. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)
HINT
Use the same procedure for the RH side and LH side.
87. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
88. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
89. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
90. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
91. INSTALL FRONT WIPER ARM HEAD CAP Installation
92. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation
93. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation
94. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH Installation
95. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH Installation
96. INSTALL FRONT SEAT ASSEMBLY
(a) for LH Side:
(1) Refer to the procedure from Install Front Seat Assembly Installation.
(b) for RH Side:
HINT
Use the same procedure for the RH side and LH side.
97. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE:
* Make sure that the cable has been disconnected from the negative (-) battery terminal for at least 2 seconds before reconnecting the cable.
* Reset the auto tilt away function setting to the previous condition by changing the customize parameter Programming and Relearning.
* When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
98. INSTALL REAR DECK FLOOR BOX Installation
99. INSTALL FRONT WHEEL LH Installation
100. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
101. ADD COOLANT (for Engine) Service and Repair
102. CHARGE WITH REFRIGERANT Service and Repair
103. WARM UP COMPRESSOR Service and Repair
104. INSPECT FOR REFRIGERANT LEAK Service and Repair
105. INSPECT FOR COOLANT LEAK Testing and Inspection
106. INSTALL COOL AIR INTAKE DUCT SEAL Installation
107. INSTALL ENGINE ROOM SIDE COVER Installation
108. INSTALL ENGINE ROOM SIDE COVER LH Installation
109. INSPECT SHIFT LEVER POSITION Adjustments
110. ADJUST SHIFT LEVER POSITION Adjustments
111. INSPECT SHIFT LEVER OPERATION Adjustments
112. INSPECT STEERING PAD Installation
113. INSPECT SUSPENSION CONTROL SYSTEM (w/ Air Suspension)
(a) Inspect the suspension control system Test Mode Procedure.
114. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light Diagnosis System.