FRONT COOLING UNIT INSTALLATION


  1. INSTALL AIR CONDITIONING UNIT


    1. Install the air conditioning unit with the 3 bolts.

      A017BCJE01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note

      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)


    1. Driver Side:


      1. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.

        Torque:
        17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    2. Passenger Side:


      1. Using a 12 mm hexagon wrench, adjust the position of the 2 collars.

        Torque:
        6.0 N*m  { 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 N*m  { 204 kgf*cm, 15 ft.*lbf }
        A017DUNE01

    3. Install the 2 bolts and 2 caps to the engine compartment side.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    5. Engage the cooler drain hose.

      A017CRX

    6. Connect the blower motor connector.

    7. Install the 2 nuts and bolt.

    8. Connect each connector.

    9. Connect the 2 earth wires with the 2 bolts <A>.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    10. Engage each clamp.

      A017FILE01

  3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT (w/ PTC Heater)


    1. Driver Side:


      1. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.

        Torque:
        17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    2. Passenger Side:


      1. Using a 12 mm hexagon wrench, adjust the position of the 2 collars.

        Torque:
        6.0 N*m  { 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 N*m  { 204 kgf*cm, 15 ft.*lbf }
        A017DUNE01

    3. Install the 2 bolts and 2 caps to the engine compartment side.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Install the instrument panel reinforcement assembly with air conditioning unit with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    5. Engage the cooler drain hose.

      A017CRX

    6. Connect the 2 quick heater connectors.

    7. Connect the blower motor connector.

    8. Install the 2 nuts and bolt.

    9. Connect each connector.

    10. Connect the 2 earth wires with the 2 bolts <A>.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    11. Engage each clamp.

      A017EURE01

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


    1. A017G8S

      Install the 3 nuts.

    2. Install the 2 bolts.

    3. Install the No. 1 instrument panel brace sub-assembly with the screw.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    4. A017D9C

      Engage each clamp.

    5. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  5. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    1. A017DTC

      Install the 3 nuts.

    2. Install the bolt.

    3. Install the No. 2 instrument panel brace sub-assembly with the screw.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    4. A017DAL

      Engage each clamp.

    5. Connect the earth wire with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  6. INSTALL CENTER HEATER TO REGISTER DUCT


    1. A017DHW

      Engage the 4 claws and install the center heater to register duct.

    2. Engage the clamp.

  7. INSTALL NO. 1 CONSOLE BOX DUCT (w/o Rear Air Conditioning System)


    1. A017EA2

      Install the clip and the No. 1 console box duct.

  8. INSTALL REAR NO. 3 AIR DUCT


    1. A017BLE

      Engage the 2 claws and install the rear No. 3 air duct.

    2. Install the clip.

    3. A017D2TE01

      Engage the claw and install the floor carpet.

  9. INSTALL REAR NO. 1 AIR DUCT


    1. A017DBG

      Engage the 2 claws and install the rear No. 1 air duct.

    2. Install the clip.

    3. Engage the clamp.

    4. A017FZ2E01

      Engage the claw and install the floor carpet.

  10. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A017DHO

      Install the air conditioning amplifier assembly with the 2 screws.

    2. Connect each connector.

  11. INSTALL ECM (for RHD)


    1. A017B1JE01

      Install the 2 ECM brackets to the ECM with the 4 screws.

    2. A017BCBE01

      Install the ECM with the ECM bracket with the bolt and 2 nuts.

      Torque:
      for LHD
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      for RHD
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Install the 2 wire harness clamps (for LHD).

    4. Install the wire harness clamp (for RHD).

    5. Connect the 6 ECM connectors.

  12. INSTALL POWER STEERING ECU ASSEMBLY (for LHD)


    1. A017FRG

      Install the power steering ECU assembly with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    2. A017C2SE01

      Check that the connector lever is at the fully unlocked position before installation.

      Note

      If the lever has been lifted out of the fully unlocked position, it may cause a faulty connection.

    3. A017FWJE01

      Connect the 4 connectors to the power steering ECU assembly.

    4. Lightly pull on the connector and check that the connector does not disconnect.

  13. INSTALL POWER STEERING ECU ASSEMBLY (for RHD)


    1. A017CHK

      Install the power steering ECU assembly with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    2. A017CK5E01

      Check that the connector lever is at the fully unlocked position before installation.

      Note

      If the lever has been lifted out of the fully unlocked position, it may cause a faulty connection.

    3. A017CK4E01

      Connect the 4 connectors to the power steering ECU assembly.

    4. Lightly pull on the connector and check that the connector will not be disconnected.

    5. Install the wire harness clamp to the power steering ECU assembly.

  14. CONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY


    1. A017C4M

      Connect the instrument panel junction block assembly with the 3 nuts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  15. INSTALL STEERING COLUMN ASSEMBLY (for LHD)


    1. A017BAIE01

      Check that the 2 bushings are securely installed to the steering column assembly.

      Tech Tips

      If the bushings are missing or damaged, replace the steering column assembly with a new one.

    2. A017BBF

      Install the steering column assembly with the bolt and 2 nuts.

      Torque:
      Bolt
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      Nut
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      There are two different bolt sizes (12 mm (0.472 in.) or 14 mm (0.551 in.)) available.

    3. Connect the connectors and engage the wire harness clamps to the steering column assembly.

    4. A017G0O

      Connect the connector to the power steering ECU assembly.

    5. A017DNH

      Connect the connector to the power steering ECU assembly.

      Tech Tips

      As shown in the illustration, securely return the lock lever to its original position to connect the connector.

  16. INSTALL STEERING COLUMN ASSEMBLY (for RHD)


    1. A017BAIE01

      Check that the 2 bushings are securely installed to the steering column assembly.

      Tech Tips

      If the bushings are missing or damaged, replace the steering column assembly with a new one.

    2. A017BCA

      Install the steering column assembly with the bolt and 2 nuts.

      Torque:
      Bolt
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      Nut
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      There are two different bolt sizes (12 mm (0.472 in.) or 14 mm (0.551 in.)) available.

    3. Connect the connectors and engage the wire harness clamps to the steering column assembly.

    4. A017DUW

      Connect the connector to the power steering ECU assembly.

    5. A017C3P

      Connect the connector to the power steering ECU assembly.

      Tech Tips

      As shown in the illustration, securely return the lock lever to its original position to connect the connector.

  17. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY


    1. A017BS1E01

      Align the matchmarks on the steering intermediate shaft sub-assembly and the power steering link assembly.

    2. A017E5L

      Install a new bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }
    3. A017CU2

      Install the steering intermediate shaft sub-assembly to the steering column hole shield.

    4. A017E6A

      Tighten the bolt.

  18. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for LHD)


    1. A017B65

      Engage the 2 claws to install the No. 1 air duct sub-assembly.

  19. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A017EX3

      Engage the 2 claws to install the No. 1 air duct sub-assembly.

  20. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY


    1. Check that the ignition switch is off.

    2. Check that the battery negative (-) cable is disconnected.

      CAUTION:

      Wait for at least 90 seconds after disconnecting the cable to prevent airbag deployment.

    3. A017F8J

      Install the DLC3 to the driver side knee airbag assembly with the 2 claws.

    4. A017EBJ

      Connect the connector to the driver side knee airbag assembly.

      Note

      When handling the airbag connector, take care not to damage the airbag wire harness.

    5. A017EHS

      Support the driver side knee airbag assembly with one hand as shown in the illustration.

    6. A017CTB

      Temporarily install the driver side knee airbag assembly with the 2 hooks.

    7. A017FEG

      Install the driver side knee airbag assembly with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  21. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (for LHD)


    1. A017EMG

      Install the brake pedal support sub-assembly with the 4 nuts.

      Torque:
      13 N*m  { 132 kgf*cm, 10 ft.*lbf }
    2. A017EDQ

      Install the brake pedal support sub-assembly to the instrument panel reinforcement with the 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    3. A017BAY

      Connect the brake pedal load sensing switch connector and engage the clamp.

  22. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (for RHD)


    1. A017ENQ

      Install the brake pedal support sub-assembly with the 4 nuts.

      Torque:
      13 N*m  { 132 kgf*cm, 10 ft.*lbf }
    2. A017BUW

      Install the brake pedal support sub-assembly to the instrument panel reinforcement with the 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    3. A017BPN

      Connect the brake pedal load sensing switch connector and engage the clamp.

  23. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS


    1. A017CCTE01

      Apply lithium soap base glycol grease to the push rod pin.

    2. Connect the brake master cylinder push rod clevis to the brake pedal with the push rod pin, and install a new clip as shown in the illustration.

  24. INSTALL BRAKE PEDAL RETURN SPRING


    1. A017F4S

      Install the brake pedal return spring between the instrument panel reinforcement and brake master cylinder push rod clevis.

  25. INSTALL STOP LIGHT SWITCH ASSEMBLY


    1. A017E1EE01

      Temporarily install the stop light switch assembly with the stop light switch lock nut.

    2. A017EYKE01

      Turn the stop light switch assembly so that the clearance between the nut end and stop light switch cushion is between 0.5 to 2.4 mm (0.020 to 0.095 in.).

    3. Tighten the stop light switch lock nut.

      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }
    4. A017BKZ

      Connect the connector.

  26. INSPECT AND ADJUST BRAKE PEDAL HEIGHT


    1. Check the brake pedal height.


      1. A017DHSE03
        Text in Illustration
        *1 Stop Light Switch Assembly
        *2 Clevis Lock Nut
        *3 Front Floor Footrest (for LHD)
        No. 2 Dash Panel Insulator Pad (for RHD)
        *a Brake Pedal Height

        Turn back the carpet.

      2. Measure the shortest distance between the brake pedal surface and front floor footrest (for LHD) or No. 2 dash panel insulator pad (for RHD).

        Pedal height (for LHD: from front floor footrest, for RHD: from No. 2 dash panel insulator pad)
        Model Specified Condition
        LHD 148.8 to 158.8 mm (5.858 to 6.252 in.)
        RHD 165.9 to 175.9 mm (6.531 to 6.925 in.)

    2. Adjust the brake pedal height.


      1. Disconnect the stop light switch connector.

      2. Remove the stop light switch assembly.

      3. Loosen the push rod clevis lock nut.

      4. Adjust the brake pedal height by turning the push rod.

      5. Tighten the push rod clevis lock nut.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      6. Install and adjust the stop light switch Click here.

        Note

        Do not depress the brake pedal.

      7. Connect the stop light switch connector.

  27. INSPECT BRAKE PEDAL FREE PLAY


    1. A017EEIE01

      Stop the engine. Depress the pedal several times until no vacuum is left in the brake booster. Release the brake pedal.

    2. Depress the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

      Pedal free play
      1.0 to 6.0 mm (0.039 to 0.236 in.)

      If the pedal free play is not as specified, check the stop light switch clearance Click here. If the pedal free play is as specified, proceed to the "INSPECT BRAKE PEDAL RESERVE DISTANCE" procedure.

  28. INSPECT BRAKE PEDAL RESERVE DISTANCE

    Tech Tips

    Measure the distance at the same point used for the brake pedal height inspection.


    1. Release the parking brake.

    2. A017EGKE13
      Text in Illustration
      *1 Front Floor Footrest (for LHD)
      No. 2 Dash Panel Insulator Pad (for RHD)
      *a Pedal Reserve Distance

      With the engine running, depress the brake pedal and measure the pedal reserve distance as shown in the illustration.

      Pedal reserve distance at 500 N (51 kgf, 112 lbf) (for LHD: from front floor footrest, for RHD: from No. 2 dash panel insulator pad)
      Model Specified Condition
      LHD 84.4 mm (3.32 in.)
      RHD 97.8 mm (3.85 in.)

      If the distance is not as specified, troubleshoot the brake system Click here.

  29. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY


    1. Engage the 5 claws.

      Note

      Do not allow the wire harness to get caught in the claws.

    2. Install the 2 bolts <D> and nut <G>.

    3. Install the 2 clips.

      A017FQ8E03

    4. Engage each clamp.

    5. Install the 2 passenger airbag bolts <A>.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    6. Connect each connector and install the instrument panel safety pad assembly.

      A017FGUE01

  30. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY


    1. Check that the ignition switch is off.

    2. Check that the battery negative (-) terminal is disconnected.

      CAUTION:

      Wait for at least 90 seconds after disconnecting the cable to prevent airbag deployment.

    3. A017CY2

      Connect the connector.

  31. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)


    1. A017CR7

      Connect the connector.

    2. Install the front No. 2 speaker assembly with the 2 bolts.

  32. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY


    1. A017EVH

      Engage the 2 guides.

    2. Engage the 2 claws and 2 clips, and install the No. 1 instrument panel speaker panel sub-assembly.

  33. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)

    Tech Tips

    Use the same procedures for the RH side and the LH side.

  34. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY


    1. A017EGG

      Engage the 2 guides.

    2. Engage the 2 claws and 2 clips, and install the No. 2 instrument panel speaker panel sub-assembly.

  35. INSTALL FRONT PILLAR GARNISH RH


    1. A017B3UE01

      Remove the protective cover.

    2. A017CDQE01

      Make sure that the front pillar garnish clip is not damaged.

      Note


      • If there is any damage, replace the garnish clip with a new one.

      • When a garnish clip is being replaced, make sure to install it in the direction shown in the illustration.

    3. Engage the 3 guides.

    4. Turn the end of the front pillar garnish clip 90° with needle-nosed pliers and install it to the front pillar garnish RH.

      Tech Tips

      Tape the tips of the needle-nosed pliers before use.

    5. A017BQI

      Engage the 2 clips to install the front pillar garnish RH.

  36. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH


    1. A017D8ZE01

      Align the alignment mark (pink) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the front door opening trim weatherstrip RH.

      Note

      After installation, check that the corners fit correctly.

  37. INSTALL FRONT PILLAR GARNISH LH


    1. A017BX5E01

      Remove the protective cover.

    2. A017E3KE01

      Make sure that the front pillar garnish clip is not damaged.

      Note


      • If there is any damage, replace the garnish clip with a new one.

      • When a garnish clip is being replaced, make sure to install it in the direction shown in the illustration.

    3. Engage the 3 guides.

    4. Turn the end of the front pillar garnish clip 90° with needle-nosed pliers and install it to the front pillar garnish LH.

      Tech Tips

      Tape the tips of the needle-nosed pliers before use.

    5. A017CU6

      Engage the 2 clips to install the front pillar garnish LH.

  38. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH


    1. A017EEJE01

      Align the alignment mark (blue) on the weatherstrip with the protruding portion on the body indicated by the arrow in the illustration, and install the front door opening trim weatherstrip LH.

      Note

      After installation, check that the corners fit correctly.

  39. INSTALL ENGINE SWITCH (w/ Smart Entry and Start System)


    1. A017G2F

      Engage the 2 claws to install the switch.

    2. Connect the switch connector.

  40. INSTALL FRONT NO. 2 CONSOLE BOX INSERT (for LHD)


    1. A017BSW

      Engage the claw and 2 guides.

    2. Install the front No. 2 console box insert with the 3 screws <E> and clip.

  41. INSTALL FRONT NO. 2 CONSOLE BOX INSERT (for RHD)


    1. A017BQH

      Engage the claw and 2 guides.

    2. Install the front No. 2 console box insert with the 3 screws <E> and clip.

  42. INSTALL FRONT NO. 1 CONSOLE BOX INSERT (for LHD)


    1. A017FLQ

      Engage the claw and 2 guides.

    2. Install the front No. 1 console box insert with the 3 screws <E> and 2 clips.

  43. INSTALL FRONT NO. 1 CONSOLE BOX INSERT (for RHD)


    1. A017BG4

      Engage the claw and 2 guides.

    2. Install the front No. 1 console box insert with the 3 screws <E> and clip.

  44. INSTALL CONSOLE BOX ASSEMBLY (w/o Rear Air Conditioning System)


    1. A017G3R

      Engage the 6 claws.

    2. A017E57

      Install the console box assembly with the 4 bolts and 2 screws.

  45. INSTALL CONSOLE BOX ASSEMBLY (w/ Rear Air Conditioning System)


    1. A017E8O

      Engage the 6 claws.

    2. Connect the connector.

    3. A017C3F

      Install the console box assembly with the 4 bolts and 2 screws.

  46. INSTALL LOWER REAR CONSOLE BOX


    1. Install the lower rear console box.

  47. INSTALL NO. 2 CONSOLE BOX DUCT (w/o Rear Air Conditioning System)


    1. A017F5N

      Install the No. 2 console box duct as shown in the illustration.

  48. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY


    1. A017FDP

      Connect the connector.

    2. Engage the 4 claws and 4 clips, and install the upper console panel sub-assembly.

  49. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY


    1. Connect each connector and clamp.

    2. A017F5K

      Engage the 4 claws and 3 clips.

    3. Install the lower instrument panel sub-assembly with the 2 bolts <B> and 3 screws <E>.

  50. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. A017F65

      Engage the 2 guides.

    2. Engage the 3 claws and install the No. 2 instrument panel under cover sub-assembly.

  51. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  52. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure for the RH side and the LH side.

  53. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Manual Air Conditioning System)


    1. A017BY3

      Connect the hood lock control cable assembly.

    2. Connect each connector.

    3. Engage the 3 claws and 10 clips.

    4. Install the lower instrument panel finish panel sub-assembly with the 2 bolts <B>.

  54. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (for Automatic Air Conditioning System)


    1. A017CWD

      Connect the hood lock control cable assembly.

    2. Connect each connector and the aspirator duct.

    3. A017EU2

      Engage the 3 claws and 10 clips.

    4. Install the lower instrument panel finish panel sub-assembly with the 2 bolts <B>.

  55. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH


    1. A017G63

      Engage the claw and clip, install the cowl side trim sub-assembly LH.

    2. Install the clip.

  56. INSTALL FRONT DOOR SCUFF PLATE LH


    1. A017B6P

      Engage the guide and 8 claws, and install the front door scuff plate LH.

  57. INSTALL MULTI-MEDIA INTERFACE ECU WITH BRACKET


    1. Install the multi-media interface ECU with bracket with the 3 nuts.

    2. Connect each connector.

  58. INSTALL RADIO RECEIVER ASSEMBLY WITH BRACKET (w/o Navigation System)


    1. Connect each connector.

    2. A017EFV

      Engage the 4 clips.

    3. A017FXP

      Install the radio receiver assembly with bracket with the 4 bolts.

  59. INSTALL NAVIGATION RECEIVER ASSEMBLY WITH BRACKET (w/ Navigation System)


    1. Connect each connector.

    2. A017CTX

      Engage the 4 clips.

    3. A017EUS

      Install the navigation receiver assembly with bracket with the 4 bolts.

  60. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY WITH BRACKET (w/o Radio Receiver)


    1. Connect each connector.

    2. A017C93

      Engage the 4 clips.

    3. Install the integration control and panel assembly with bracket with the 4 bolts <D>.

  61. INSTALL HEATER CONTROL AND ACCESSORY ASSEMBLY (for Manual Air Conditioning System)


    1. Connect the connector.

    2. A017G04

      Engage the 4 clips and install the heater control and accessory assembly.

  62. INSTALL AIR CONDITIONING CONTROL ASSEMBLY (for Automatic Air Conditioning System)


    1. Connect the connector.

    2. A017EE0

      Engage the 4 clips and install the air conditioning control assembly.

  63. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/o Smart Entry and Start System)


    1. A017EYQE01

      Apply protective tape to the areas shown in the illustration.

    2. Connect each connector.

    3. Engage the 10 claws and 8 clips, and install the center instrument cluster finish panel assembly.

      Note

      Do not the damage the instrument panel safety pad assembly and lower instrument panel finish panel sub-assembly.

  64. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (w/ Smart Entry and Start System)


    1. A017D5UE01

      Apply protective tape to the areas shown in the illustration.

    2. Connect each connector.

    3. Engage the 10 claws and 8 clips, and install the center instrument cluster finish panel assembly.

      Note

      Do not the damage the instrument panel safety pad assembly and lower instrument panel finish panel sub-assembly.

  65. INSTALL CENTER INSTRUMENT PANEL REGISTER ASSEMBLY


    1. A017DC8

      Engage the 2 claws and 5 clips, and install the center instrument panel register assembly.

  66. INSTALL COMBINATION METER ASSEMBLY


    1. Connect the connector.

    2. A017EG5

      Install the combination meter assembly with the 4 screws <E>.

  67. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY


    1. A017EQX

      Engage the 4 claws and 4 clips, and install the instrument cluster finish panel assembly.

  68. POSITION FRONT WHEELS STRAIGHT AHEAD

  69. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY


    1. A017EZZ

      Using pliers, engage the claw. Install the turn signal switch assembly with spiral cable sub-assembly to the steering column assembly.

    2. Connect the connectors to the turn signal switch assembly with spiral cable sub-assembly.

  70. INSTALL STEERING COLUMN COVER


    1. A017BQ8

      Engage the claw to install the upper steering column cover.

    2. A017D1F

      Engage the 2 claws to install the lower steering column cover.

    3. A017BZ5

      Install the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  71. ADJUST SPIRAL CABLE SUB-ASSEMBLY


    1. Check that the ignition switch is off.

    2. Check that the battery negative (-) cable is disconnected.

      CAUTION:

      Wait for at least 90 seconds after disconnecting the cable to prevent airbag deployment.

    3. A017CHQ

      Rotate the spiral cable counterclockwise slowly by hand until it stops.

      Note

      Do not turn the spiral cable using the airbag wire harness.

    4. A017E7ME01

      Rotate the spiral cable clockwise approximately 2.5 turns to align the marks.

      Note

      Do not turn the spiral cable using the airbag wire harness.

      Tech Tips

      The spiral cable will rotate approximately 2.5 turns to both the left and right from the center.

  72. INSTALL STEERING WHEEL ASSEMBLY


    1. A017E10E01

      Align the matchmarks on the steering wheel assembly and steering main shaft.

    2. Install the steering wheel assembly set nut.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    3. Connect the connectors to the spiral cable sub-assembly.

  73. INSPECT STEERING WHEEL CENTER POINT

  74. INSTALL STEERING PAD


    1. Check that the ignition switch is off.

    2. Check that the battery negative (-) terminal is disconnected.

      CAUTION:

      Wait for at least 90 seconds after disconnecting the cable to prevent airbag deployment.

    3. A017C2G

      Support the steering pad with one hand as shown in the illustration.

    4. A017FLZ

      Connect the 2 airbag connectors to the steering pad.

      Note

      When handling the airbag connector, take care not to damage the airbag wire harness.

    5. Connect the horn connector to the steering pad.

    6. Confirm that the circumference groove of the "TORX" screw fits in the screw case, and place the steering pad onto the steering wheel assembly.

    7. A017EQKE01

      Using a "TORX" socket wrench (T30), tighten the 2 "TORX" screws.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  75. INSTALL LOWER NO. 2 STEERING WHEEL COVER


    1. A017BJG

      Install the lower No. 2 steering wheel cover with the claw.

  76. INSTALL LOWER NO. 3 STEERING WHEEL COVER


    1. A017F4M

      Install the lower No. 3 steering wheel cover with the claw.

  77. CONNECT COOLER REFRIGERANT LIQUID PIPE A


    1. Remove the attached vinyl tape from the pipe.

    2. 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

    3. Install the O-ring on the cooler refrigerant liquid pipe A.

    4. Install the cooler refrigerant liquid pipe A.

  78. CONNECT NO. 1 COOLER REFRIGERANT SUCTION PIPE


    1. Remove the attached vinyl tape from the pipe.

    2. 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

    3. Install the O-ring on the No. 1 cooler refrigerant suction pipe.

    4. A017EH4

      Move the hook connector in the direction indicated by the arrow in the illustration.

    5. Insert the pipe joint into the fitting hole securely and tighten the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  79. CONNECT HEATER INLET WATER HOSE


    1. A017C1F

      Install the heater inlet water hose and attach the clip.

  80. CONNECT HEATER OUTLET WATER HOSE


    1. A017CZP

      Install the heater outlet water hose and attach the clip.

  81. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY


    1. A017F9GE01

      Install the outer cowl top panel sub-assembly with the 8 bolts and 6 nuts.

      Torque:
      Nut A
      85 N*m  { 866 kgf*cm, 63 ft.*lbf }
      Bolt B
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      Nut C
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
    2. A017G69

      Engage the 4 clamps.

  82. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A017FR2

      Install the windshield wiper motor and link assembly with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the connector.

  83. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Engage the 20 claws.

      A017F5J

    2. Install the cowl top ventilator louver sub-assembly with the 2 clips.

    3. A017EML

      Engage the 2 claws and connect the front fender to cowl side seal LH.

    4. A017F5E

      Engage the 2 claws and connect the front fender to cowl side seal RH.

  84. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. When reinstalling:


      1. A017C5CE01

        Clean the wiper arm serrations.

      2. Clean the wiper pivot serrations with a wire brush.

    3. A017D7ZE01

      Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the wiper arm by hand when tightening the nut.

      Area Measurement
      A 25.6 mm (1.00 in.)

  85. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. When reinstalling:


      1. A017C5CE01

        Clean the wiper arm serrations.

      2. Clean the wiper pivot serrations with a wire brush.

    3. A017D4VE01

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the wiper arm by hand when tightening the nut.

      Area Measurement
      A 31.9 mm (1.26 in.)

    4. Operate the front wipers while spraying washer fluid onto the windshield glass. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

  86. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  87. INSPECT STEERING PAD


    1. A017FBN

      With the steering pad installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the steering pad with a new one:


      • Cuts, minute cracks or marked discoloration on the steering pad top surface or grooves.

    2. Make sure that the horn sounds.

      Tech Tips

      If the horn does not sound, inspect the horn system Click here.

  88. INSPECT SRS WARNING LIGHT


    1. Inspect the SRS warning light Click here.

  89. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for cylinder block drain cock plugs }

    3. Loosen the air drain cock plug from the water inlet housing.

    4. A017G9AE01

      Loosen the air drain plug at the top of the radiator 3 or 4 turns.

    5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for air drain cock plug }

    6. Continue to add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the radiator air drain hole. Then close the air drain plug at the top of the radiator.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf, for air drain plug }

      Tech Tips

      If the coolant level at the radiator inlet opening drops after squeezing the No. 1 and No. 2 radiator hoses, add coolant.

    7. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Standard capacity
      Condition Specified Condition
      w/ Rear Heater 11.7 liters (12.4 US qts, 10.3 Imp. qts)
      w/o Rear Heater 9.5 liters (10.1 US qts, 8.4 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    8. Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

    9. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    10. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by squeezing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When squeezing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

        Note


        • Make sure that the radiator reservoir still has some coolant in it.

        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • If there is not enough coolant, the engine may overheat or be seriously damaged.

        • If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line.

    11. Stop the engine and wait until the engine coolant cools down.

    12. Add engine coolant to the FULL line on the radiator reservoir.

  90. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. A017G83

      Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  91. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A017FV6E02
      Standard (w/o Rear Air Conditioning System)
      550 to 650 g (19.4 to 22.9 oz.)
      Standard (w/ Rear Air Conditioning System)
      720 to 820 g (25.4 to 28.9 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.

      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

  92. WARM UP ENGINE


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  93. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant gas, inspect for refrigerant leak using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Make sure that the ignition switch is off.

      • Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A017BY0E25

      Using a gas leak detector, inspect for refrigerant leak from the refrigerant lines.

    4. A017DL2E06

      Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

    5. If a gas leak is not detected from the drain hose, remove the blower motor from the cooling unit. Insert the gas leak detector into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

  94. INITIALIZE SERVO MOTOR


    1. Turn the ignition switch off.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to on.

    4. Press the A/C OFF switch.

    5. Turn the intelligent tester on.

    6. Enter the following menus: Body / Air Conditioner / Utility / Servomotor Initialization.

    7. According to the intelligent tester display, select the "Next" switch.

    8. According to the intelligent tester display, select the "Next" switch.

      Tech Tips

      During initialization, the AUTO indicator illuminates. When initialization is complete, the indicator turns off.

    9. According to the intelligent tester display, select the exit to finish the initialization.