UNLOCK WARNING SWITCH INSTALLATION


  1. INSTALL UNLOCK WARNING SWITCH ASSEMBLY


    1. A017B1OE02

      Engage the 2 claws to install the un-lock warning switch assembly to the steering lock sub-assembly.

  2. INSTALL IGNITION SWITCH LOCK CYLINDER ASSEMBLY


    1. Make sure that the ignition switch lock cylinder assembly is in the ACC position.

    2. A017FDYE02

      Install the ignition switch lock cylinder assembly to the steering lock sub-assembly.

    3. Make sure that the ignition switch lock cylinder assembly is securely installed.

  3. INSPECT STEERING LOCK OPERATION


    1. A017FZD

      Check that the steering lock mechanism is activated when the key is removed.

    2. A017DCNE02

      Check that the steering lock mechanism is deactivated when the key is inserted and turned to the ACC position.

      Tech Tips

      If there is any abnormality, replace the ignition switch lock cylinder assembly.

  4. INSTALL STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY


    1. Temporarily install the assembled steering lock and its bracket to the steering column assembly with 2 new tapered-head bolts.

    2. A017D4D

      Tighten the 2 tapered-head bolts until the bolt heads break off.

  5. INSTALL TRANSPONDER KEY AMPLIFIER


    1. A017BM6

      Align the transponder key amplifier with the upper bracket. Tilt the amplifier slightly and slide it into the position as shown in the illustration.

    2. Push the transponder key amplifier to install it to the upper bracket with the 2 claws.

      Note

      Do not push the amplifier with excessive force.

  6. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A017CSKE01

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

    2. A017FJR

      Install a new bolt.

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

  7. 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.

  8. 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.

  9. 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.

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


    1. A017B65

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

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


    1. A017EX3

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

  12. POSITION FRONT WHEELS STRAIGHT AHEAD

  13. 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.

  14. 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 }

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  21. 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.

  22. 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.

  23. 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 }

  24. 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>.

  25. 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>.

  26. 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.

  27. INSTALL FRONT DOOR SCUFF PLATE LH


    1. A017B6P

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

  28. ADJUST SPIRAL CABLE


    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.

  29. 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.

  30. INSPECT STEERING WHEEL CENTER POINT

  31. 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 }

  32. INSTALL LOWER NO. 3 STEERING WHEEL COVER


    1. A017F4M

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

  33. INSTALL LOWER NO. 2 STEERING WHEEL COVER


    1. A017BJG

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

  34. INSTALL FRONT WHEEL LH

  35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  36. 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.

  37. INSPECT SRS WARNING LIGHT


    1. Inspect the SRS warning light Click here.