BLOWER UNIT INSTALLATION


  1. INSTALL BLOWER ASSEMBLY


    1. A01630OE02

      Install the blower assembly with the 2 claws and screw.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

    2. Connect the connector.

  2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY


    1. A015YST

      Install the air conditioning amplifier with the screw and connect the connector.

  3. INSTALL NO. 2 AIR DUCT


    1. A01639X

      Install the No. 2 air duct with the screw.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  4. INSTALL AIR CONDITIONER UNIT ASSEMBLY


    1. Install the air conditioner unit assembly with the 3 bolts(1) and 2 screws.

      A015ZWBE01
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf, (BOLT 1) }

  5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY


    1. Driver seat side:

      A0160M8E04

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

    2. Passenger seat side:


      1. Using a 12 mm hexagon wrench, install the instrument panel reinforcement with the 2 collars.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      2. Using a T40 "TORX" socket, install the instrument panel reinforcement with the 2 "TORX" bolts.

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

    3. Install the instrument panel reinforcement with the 3 bolts and nut(1).

      A015ZT4E02
      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf, (NUT 1) }

    4. Install the bolt and cap.

    5. Connect the 19 connectors and attach the 27 clamps.

    6. Install the 2 junction blocks with the 2 bolts and nut.

      A01638C

  6. INSTALL DEFROSTER NOZZLE LOWER ASSEMBLY


    1. A016127E01

      Attach the 4 claws to install the defroster nozzle lower.

  7. INSTALL SKID CONTROL ECU


    1. A0162A6E02

      Install the skid control ECU with the 3 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      Tech Tips


      • Align positioning boss (A) of the blower assembly with the hole of the skid control ECU.

      • Securely engage hook (B) of the skid control ECU with the blower assembly.

    2. A01605Q

      Connect the 3 connectors to the skid control ECU.

  8. INSTALL STEERING COLUMN ASSEMBLY


    1. A015YSE

      Install the steering column assembly with the 4 nuts.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

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

    3. A015ZJW

      Install the clamp to the steering column hole shield.

  9. INSTALL BRAKE PEDAL RETURN SPRING


    1. A01603J

      Install the brake pedal return spring.

  10. INSTALL NO. 1 AIR DUCT


    1. A015ZE9

      Engage the 2 claws to install the No. 1 air duct.

  11. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY


    1. A01632ME10

      Align the matchmarks on the steering sliding yoke sub-assembly and the power steering link assembly.

    2. A015ZNKE02

      Install the bolt (A) and tighten the 2 bolts.

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

  12. INSTALL INSTRUMENT PANEL STAY


    1. Engage the claw to install the instrument panel stay.

      A015YQB

  13. INSTALL INSTRUMENT PANEL CLIP


    1. Engage the 4 claws to install the 4 instrument panel clips.

      A0161ND

  14. 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. Engage the 2 clamps.

    3. Install the 2 passenger airbag bolts <A> or <B>.

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

    4. Install the 6 bolts <C> and nut <G>.

      A0162ENE01

    5. Engage the 2 claws and install the cooler thermistor.

    6. Engage the clamps.

    7. Connect the connectors and install the instrument panel safety pad assembly.

      A0162ST

  15. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY


    1. Check that the engine switch is off.

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. A015Z67E02

      Connect the connector.

      Note

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

  16. INSTALL NO. 1 CONSOLE BOX DUCT


    1. A01639E

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

  17. INSTALL NO. 2 CONSOLE BOX DUCT


    1. A0162NO

      Install the No. 2 console box duct with the 2 clips.

  18. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY (w/ Front Center Speaker)


    1. Connect the connector.

    2. A01626SE01

      Install the front stereo component speaker assembly with the 2 bolts.

      Tech Tips

      Install the bolts in the order shown in the illustration.

  19. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY


    1. A0163EN

      Engage the 7 claws and 2 clips to install the No. 3 instrument panel speaker panel sub-assembly.

  20. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY


    1. A0161QU

      Connect the connector.

    2. Engage the 4 claws and 2 clips to install the No. 2 instrument panel register assembly.

  21. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY


    1. A0161JS

      Connect the connector.

    2. Engage the 7 claws and 2 clips to install the No. 1 instrument panel register assembly.

  22. INSTALL FRONT PILLAR GARNISH LH


    1. A0162T2E01

      Install a new clip <A> on the front pillar garnish LH.

    2. Engage the claw and 2 clips, and install the front pillar garnish LH.

  23. INSTALL FRONT PILLAR GARNISH RH

    Tech Tips

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

  24. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY


    1. A01605K

      Connect the connectors.

    2. Engage the 2 claws.

    3. Install the glove compartment door assembly with the 5 screws <D>.

  25. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY


    1. Check that the engine switch is off.

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. A0160QYE01

      Connect the front passenger side knee airbag connector to the front passenger side knee airbag assembly.

      Note

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

    4. Install the front passenger side knee airbag assembly with the 3 bolts and claw.

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

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


    1. A015YZF

      Engage the 4 clips to install the No. 2 instrument panel under cover sub-assembly.

  27. INSTALL SIDE INSTRUMENT PANEL RH


    1. A015ZMM

      Engage the 5 claws and 3 clips to install the side instrument panel RH.

  28. INSTALL FRONT DOOR OPENING TRIM COVER RH

    Tech Tips

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

  29. INSTALL FRONT DOOR SCUFF PLATE RH

    Tech Tips

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

  30. INSTALL COMBINATION METER ASSEMBLY


    1. A0160R9

      Connect the connectors.

    2. Engage the 2 claws and install the combination meter assembly.

  31. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY


    1. A0162U1

      Install the instrument cluster finish panel sub-assembly with the 2 screws <F> and 2 clips.

  32. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY


    1. Check that the engine switch is off.

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. Connect the driver side knee airbag connector to the driver side knee airbag assembly.

      Note

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

    4. A0161L3

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

    5. A0160VX

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    6. A0160SH

      Install the hood lock control cable with the claw.

  33. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY


    1. A0160VQ

      Connect the connectors.

    2. Engage the 7 clips to install the lower instrument panel finish panel sub-assembly.

  34. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. A015ZC2E01

      Connect the connectors.

    2. Insert the No. 1 instrument panel under cover sub-assembly into the guide as shown in the illustration.

    3. Engage the 2 claws.

    4. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <D>.

  35. INSTALL SIDE INSTRUMENT PANEL LH


    1. A015ZMU

      Engage the 5 claws and 3 clips to install the side instrument panel LH.

  36. INSTALL FRONT DOOR OPENING TRIM COVER LH


    1. A016285

      Engage the 4 claws and install the front door opening trim cover LH.

  37. INSTALL FRONT DOOR SCUFF PLATE LH


    1. A015ZPR

      Engage the 4 clips.

    2. A0161H2

      Engage the 7 claws and install the front door scuff plate LH.

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


    1. A0161XDE01

      Install the turn signal switch assembly with spiral cable sub-assembly to the steering column assembly with the clamp.

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

  39. INSTALL STEERING COLUMN COVER


    1. A015YPR

      Engage the 4 clips and 2 guides to install the upper steering column cover onto the instrument panel cluster finish panel.

    2. A015YO2

      Engage the claw to install the upper steering column cover.

    3. A0162IK

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

      Note

      Do not damage the tilt and telescopic switch.

    4. A0160S7

      Install the 3 screws.

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

  40. ADJUST SPIRAL CABLE SUB-ASSEMBLY


    1. Check that the engine switch is off.

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. A01602L

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

      Note

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

    4. A015YXZE04

      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.

  41. INSTALL STEERING WHEEL ASSEMBLY


    1. A015YNDE01

      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.

  42. INSTALL STEERING PAD


    1. Check that the engine switch is off.

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. A015YZ8

      Connect the 2 airbag connectors to the steering pad.

      Note


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

      • Be sure to only connect the connectors to each corresponding color.

    4. Connect the horn connector to the steering pad.

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

    6. A01600XE01

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

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

  43. INSTALL LOWER NO. 3 STEERING WHEEL COVER


    1. A015ZUQ

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

  44. INSTALL LOWER NO. 2 STEERING WHEEL COVER


    1. A0160QU

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

  45. INSTALL INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System)


    1. Connect each connector.

    2. A015ZQC

      Install the integration control panel with radio receiver assembly with the 4 bolts.

  46. INSTALL MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System)


    1. Connect each connector.

    2. A0162FS

      Install the the multi-display with radio receiver assembly with the 4 bolts.

  47. INSTALL CENTER LOWER INSTRUMENT CLUSTER FINISH PANEL


    1. A0160J3

      Engage the 4 claws to install the center lower instrument cluster finish panel.

  48. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY


    1. A015Z29

      for LHD:


      1. Connect the connectors.

    2. A0160I2

      for RHD:


      1. Connect the connectors.

      2. Engage the 3 clamps.

    3. A0162RW

      Engage the 11 claws to install the No. 3 instrument panel register assembly.

  49. INSTALL CONSOLE BOX


    1. A0162J5

      Engage the 2 claws and 2 clips.

    2. A015ZEK

      Install the 2 bolts.

    3. A0162NA

      Install the 2 bolts.

    4. Connect the connector.

    5. A0160S1

      Connect the 2 connectors.

    6. Engage the 2 clamps.

    7. Install the 2 bolts.

  50. INSTALL CONSOLE BOX REGISTER ASSEMBLY


    1. A01638Q

      Engage the 2 claws and 4 clips, and then install the console box register assembly.

  51. INSTALL REAR ASH RECEPTACLE ASSEMBLY


    1. Install the rear ash receptacle assembly.

  52. INSTALL FRONT ASH RECEPTACLE ASSEMBLY


    1. A0161X0E01

      Connect the connectors.

    2. Insert the protruding parts of the front ash receptacle assembly into the 2 guide holes as shown in the illustration.

    3. A0161L2

      Install the front ash receptacle assembly with the 2 screws <E>.

  53. INSTALL CONSOLE PANEL SUB-ASSEMBLY


    1. A0162AI

      Connect the connectors.

    2. Engage the 8 clips to install the console panel sub-assembly.

  54. INSTALL UPPER NO. 2 CONSOLE PANEL GARNISH


    1. A0163A0

      Engage the claw and 2 clips to install the upper No. 2 console panel garnish.

  55. INSTALL UPPER NO. 1 CONSOLE PANEL GARNISH


    1. A01626T

      Engage the claw and 2 clips to install the upper No. 1 console panel garnish.

  56. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. A015ZOR

      Turn the shift lever knob clockwise and install the shift lever knob sub-assembly.

  57. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A0161NE

      Install the windshield wiper motor and link assembly with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Connect the connector.

  58. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Engage the 11 claws.

      A015ZI2
    2. A015ZRH

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

  59. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


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

    2. A0161WUE01

      Clean the wiper arm serrations.

    3. Clean the wiper pivot serrations with a wire brush (when reinstalling).

    4. A0160ONE01

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

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

      Area Measurement
      A 15 to 30 mm (0.591 to 1.18 in.)
      B Approx. 40 mm (1.57 in.)

  60. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


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

    2. A0161WUE01

      Clean the wiper arm serrations.

    3. Clean the wiper pivot serrations with a wire brush (when reinstalling).

    4. A0162P6E01

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

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

      Tech Tips

      Hold the arm hinge by hand to fasten the nut.

      Area Measurement
      A 16 to 31 mm (0.630 to 1.22 in.)
      B Approx. 20 mm (0.787 in.)

    5. Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

  61. INSTALL FRONT WIPER ARM HEAD CAP


    1. A015YS0

      Install the front wiper arm head cap.

      Tech Tips

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

  62. INSTALL ROOF DRIP SIDE FINISH MOULDING LH


    1. Engage the 2 clips and install the center roof drip side finish moulding.

      A0163FV

  63. INSTALL ROOF DRIP SIDE FINISH MOULDING RH

    Tech Tips

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

  64. INSTALL FRONT UPPER FENDER PROTECTOR LH


    1. A0162I4

      Engage the claw and the 4 clips and install the front upper fender protector LH.

    2. Engage the clip on the rubber portion of the cowl top ventilator louver sub-assembly with the front upper fender protector LH.

  65. INSTALL FRONT UPPER FENDER PROTECTOR RH

    Tech Tips

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

  66. INSTALL HEATER WATER INLET HOSE


    1. Install the water hose and attach the clip.

  67. INSTALL HEATER WATER OUTLET HOSE

    Tech Tips

    Use the same procedure for the water hose inlet.

  68. INSTALL COOLER REFRIGERANT LIQUID PIPE A


    1. Remove the vinyl tape attached to the pipe.

    2. Sufficiently apply compressor oil to a new O-ring and the 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 to the fitting hole.

  69. INSTALL SUCTION PIPE SUB-ASSEMBLY


    1. Remove the vinyl tape attached to the pipe.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe sub-assembly.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the suction pipe sub-assembly.

    4. A0163GJ

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

    5. Insert the pipe joints into the fitting holes securely and tighten the bolt.

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

  70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  71. CHARGE REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      400 to 500g (14.10 to 17.63 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
      A015ZSYE02

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.


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

  72. WARM UP ENGINE


    1. Warm up the engine at less than 1570 rpm for 2 minutes or more after charging the refrigerant.

      Note

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

  73. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under the following conditions:


      • Stop the engine.


      • Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).


      • Repeat the test 2 or 3 times.


      • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A016150E10

      Using a gas leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

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

  74. INSTALL ENGINE ROOM SIDE COVER LH (for LHD)


    1. A016120

      Install the engine room side cover LH with the 5 clips.

  75. INSTALL ENGINE ROOM SIDE COVER LH (for RHD)


    1. A015Z63

      Install the engine room side cover LH with the 4 clips.

  76. INSTALL ENGINE ROOM SIDE COVER RH (for LHD)


    1. A0161AL

      Install the engine room side cover RH with the 3 clips.

  77. INSTALL ENGINE ROOM SIDE COVER RH (for RHD)


    1. A015YK3

      Install the engine room side cover RH with the 4 clips.

  78. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A01638L

      Install the cool air intake duct seal with the 9 clips.