Installation
AIR CONDITIONING: FRONT COOLING UNIT: INSTALLATION
1. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit with the 3 bolts.
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 INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/o PTC Heater)
(a) Driver Side:
(1) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.
Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)
(b) Passenger Side:
(1) Using a 12 mm hexagon wrench, adjust the position of the 2 collars.
Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
(2) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "TORX" bolts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(c) Connect the connector.
(d) Install the 2 bolts and 2 caps to the engine compartment side.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(e) Install the instrument panel reinforcement assembly with air conditioning unit with the nut.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(f) Engage the cooler drain hose.
(g) Connect the blower motor connector.
(h) Install the 2 nuts and bolt.
(i) Connect each connector.
(j) Connect the 2 earth wires with the 2 bolts [A].
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(k) Engage each clamp.
3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/ PTC Heater)
(a) Driver Side:
(1) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.
Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)
(b) Passenger Side:
(1) Using a 12 mm hexagon wrench, adjust the position of the 2 collars.
Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
(2) Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "TORX" bolts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(c) Connect the connector.
(d) Install the 2 bolts and 2 caps to the engine compartment side.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(e) Install the instrument panel reinforcement assembly with air conditioning unit with the nut.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(f) Engage the cooler drain hose.
(g) Connect the 2 quick heater connectors.
(h) Connect the blower motor connector.
(i) Install the 2 nuts and bolt.
(j) Connect each connector.
(k) Connect the 2 earth wires with the 2 bolts [A].
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(l) Engage each clamp.
4. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the 3 nuts.
(b) Install the 2 bolts.
(c) Install the No. 1 instrument panel brace sub-assembly with the screw.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(d) Engage each clamp.
(e) Connect the earth wire with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the 3 nuts.
(b) Install the bolt.
(c) Install the No. 2 instrument panel brace sub-assembly with the screw.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(d) Engage each clamp.
(e) Connect the earth wire with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
6. INSTALL CENTER HEATER TO REGISTER DUCT
(a) Engage the 4 claws and install the center heater to register duct.
(b) Engage the clamp.
7. INSTALL NO. 1 CONSOLE BOX DUCT (w/o Rear Air Conditioning System)
(a) Install the clip and the No. 1 console box duct.
8. INSTALL REAR NO. 3 AIR DUCT
(a) Engage the 2 claws and install the rear No. 3 air duct.
(b) Install the clip.
(c) Engage the claw and install the floor carpet.
9. INSTALL REAR NO. 1 AIR DUCT
(a) Engage the 2 claws and install the rear No. 1 air duct.
(b) Install the clip.
(c) Engage the clamp.
(d) Engage the claw and install the floor carpet.
10. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Installation
11. INSTALL CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (w/ Smart Key System) Installation
12. INSTALL POWER STEERING ECU ASSEMBLY Installation
13. CONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY
(a) Connect the instrument panel junction block assembly with the 3 nuts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
14. INSTALL STEERING COLUMN ASSEMBLY Installation
15. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation
16. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY Installation
17. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY Installation
18. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY Installation
19. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS Installation
20. INSTALL BRAKE PEDAL RETURN SPRING Installation
21. INSTALL STOP LIGHT SWITCH ASSEMBLY Installation
22. INSPECT AND ADJUST BRAKE PEDAL HEIGHT Adjustments
23. INSPECT BRAKE PEDAL FREE PLAY Adjustments
24. INSPECT BRAKE PEDAL RESERVE DISTANCE Adjustments
25. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for Pole Antenna Type) Installation
26. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (for Glass Antenna Type) Installation
27. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY Installation
28. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side) Installation
29. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation
30. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side) Installation
31. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY Installation
32. INSTALL FRONT PILLAR GARNISH RH Installation
33. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation
34. INSTALL FRONT PILLAR GARNISH LH Installation
35. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation
36. INSTALL ENGINE SWITCH (w/ Smart Key System) Installation
37. INSTALL FRONT NO. 2 CONSOLE BOX INSERT Installation
38. INSTALL FRONT NO. 1 CONSOLE BOX INSERT Installation
39. INSTALL CONSOLE BOX ASSEMBLY (w/o Rear Air Conditioning System) Installation
40. INSTALL CONSOLE BOX ASSEMBLY (w/ Rear Air Conditioning System) Installation
41. INSTALL LOWER REAR CONSOLE BOX Installation
42. INSTALL NO. 2 CONSOLE BOX DUCT (w/o Rear Air Conditioning System) Installation
43. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY Installation
44. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation
45. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
46. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH Installation
47. INSTALL FRONT DOOR SCUFF PLATE RH Installation
48. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Manual Air Conditioning System) Installation
49. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Automatic Air Conditioning System) Installation
50. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH Installation
51. INSTALL FRONT DOOR SCUFF PLATE LH 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 HEATER CONTROL AND ACCESSORY ASSEMBLY (for Manual Air Conditioning System) Installation
55. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System) Installation
56. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/o Smart Key System) Installation
57. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/ Smart Key System) Installation
58. INSTALL CENTER INSTRUMENT PANEL REGISTER ASSEMBLY Installation
59. INSTALL COMBINATION METER ASSEMBLY Installation
60. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY Installation
61. POSITION FRONT WHEELS STRAIGHT AHEAD
62. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY Installation
63. INSTALL STEERING COLUMN COVER Installation
64. ADJUST SPIRAL CABLE Installation
65. INSTALL STEERING WHEEL ASSEMBLY Installation
66. INSPECT STEERING WHEEL CENTER POINT
67. INSTALL STEERING PAD Installation
68. INSTALL LOWER NO. 2 STEERING WHEEL COVER Installation
69. INSTALL LOWER NO. 3 STEERING WHEEL COVER Installation
70. INSTALL FRONT WHEEL LH Installation
71. CONNECT COOLER REFRIGERANT LIQUID PIPE A
(a) Remove the attached vinyl tape from the pipe.
(b) Sufficiently apply compressor oil to a new O-ring and fitting surface of the cooler refrigerant liquid pipe A.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the cooler refrigerant liquid pipe A.
(d) Install the cooler refrigerant liquid pipe A.
72. CONNECT NO. 1 COOLER REFRIGERANT SUCTION PIPE
(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 No. 1 cooler refrigerant suction pipe.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the O-ring on the No. 1 cooler refrigerant suction pipe.
(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)
73. CONNECT HEATER INLET WATER HOSE
(a) Install the heater inlet water hose and attach the clip.
74. CONNECT HEATER OUTLET WATER HOSE
(a) Install the heater outlet water hose and attach the clip.
75. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
76. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
77. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
78. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
79. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
80. 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.
81. INSPECT STEERING PAD Installation
82. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light Diagnosis System.
83. ADD ENGINE COOLANT (for 1AR-FE) Service and Repair
84. ADD ENGINE COOLANT (for 2GR-FE) Service and Repair
85. INSPECT FOR COOLANT LEAK (for 1AR-FE) Testing and Inspection
86. INSPECT FOR COOLANT LEAK (for 2GR-FE) Testing and Inspection
87. CHARGE WITH REFRIGERANT Service and Repair
88. WARM UP ENGINE Service and Repair
89. INSPECT FOR REFRIGERANT LEAK Service and Repair
90. INITIALIZE SERVO MOTOR
(a) Turn the ignition switch off.
(b) Connect the Techstream to the DLC3.
(c) Turn the ignition switch to on.
(d) Press the A/C OFF switch.
(e) Turn the Techstream on.
(f) Enter the following menus: Body Electrical / Air Conditioner / Utility / Servomotor Initialization.
(g) According to the Techstream display, select the "Next" switch.
(h) According to the Techstream display, select the "Next" switch.
HINT
During initialization, the AUTO indicator illuminates. When initialization is complete, the indicator turns off.
(i) According to the Techstream display, select the exit to finish the initialization.