Installation

AIR CONDITIONING: AIR CONDITIONING UNIT: INSTALLATION

INSTALLATION

1. INSTALL AIR CONDITIONING UNIT
(a) Install the air conditioning unit with the 3 screws.

2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
(a) Engage the claw and install the air conditioning amplifier as shown in the illustration.
(b) Install the screw.
3. INSTALL INSTRUMENT PANEL REINFORCEMENT (for Manual Transaxle)

(a) Temporarily tighten the air conditioning unit with the 3 screws.
(b) Install the instrument panel reinforcement and the air conditioning unit with the 9 bolts.
Torque: 24 Nm (241 kgf-cm, 17 ft-lbf)for Bolt A

(c) Install the 3 screws, 3 bolts and nut in the sequence shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)for screw
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)for nut
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)for bolt
4. INSTALL INSTRUMENT PANEL REINFORCEMENT (for Automatic Transaxle)

(a) Temporarily tighten the air conditioning unit with the 3 screws.
(b) Install the instrument panel reinforcement and the air conditioning unit with the 8 bolts.

(c) Install the 3 screws, 3 bolts and nut in the sequence shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)for screw A
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)for nut
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)for bolt
5. INSTALL INSTRUMENT PANEL WIRE
(a) Install the wire harness with the clamps and connectors.

(b) Install the ground wire with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)

(d) Install the connector holder with the bolt.
Torque: 3.2 Nm (33 kgf-cm, 28 in-lbf)
6. INSTALL MAIN BODY ECU

(a) Install the main body ECU with the 2 bolts.
Torque: 3.2 Nm (33 kgf-cm, 28 in-lbf)

(b) Connect the 5 connectors and the 3 clamps.
7. CONNECT DRAIN COOLER HOSE

(a) Install the drain hose into the position shown in the illustration.
NOTICE:
- Install the drain hose with its UP mark facing upward, within the 90 degree range shown in the illustration.
- Install the drain hose without twisting it.

8. INSTALL REAR NO. 3 AIR DUCT

(a) Engage the 4 claws and install the air duct.

9. INSTALL INSTRUMENT PANEL BRACE SUB-ASSEMBLY
(a) Install the instrument panel brace with the bolt, screw and nut.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) Install the PTC heater wire with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(c) Engage the 3 clamps.
10. INSTALL REAR NO. 2 AIR DUCT

(a) Engage the 4 claws and install the air duct.
11. INSTALL REAR NO. 1 AIR DUCT

(a) Engage the 2 claws and install the air duct.
12. INSTALL DEFROSTER NOZZLE ASSEMBLY

(a) Engage the 5 claws and install the defroster nozzle.
13. INSTALL NO. 6 HEATER TO REGISTER DUCT ASSEMBLY

(a) Engage the 3 claws and install the heater to register duct.
14. INSTALL STEERING COLUMN ASSEMBLY Installation
15. INSTALL BRAKE PEDAL SUPPORT Installation
16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS Installation

17. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
(a) Align the matchmarks and install the sliding yoke onto the steering gear assembly with bolt B.
Torque: 35 Nm (360 kgf-cm, 26 ft-lbf)
(b) Tighten bolt A.
Torque: 35 Nm (360 kgf-cm, 26 ft-lbf)
18. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
19. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT Installation
20. CONNECT POWER STEERING ECU ASSEMBLY Installation
21. INSTALL COMBINATION SWITCH ASSEMBLY Installation
22. INSTALL STEERING COLUMN UPPER COVER Installation
23. INSTALL STEERING COLUMN LOWER COVER Installation
24. INSTALL STEERING WHEEL ASSEMBLY Installation
25. INSTALL STEERING PAD Installation
26. INSTALL LOWER INSTRUMENT PANEL Installation
27. CONNECT ANTENNA CORD SUB-ASSEMBLY Installation
28. CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY Installation
29. INSTALL NO. 1 RADIO BRACKET Installation
30. INSTALL NO. 2 RADIO BRACKET Installation
31. INSTALL INSTRUMENT PANEL BOX Installation
32. INSTALL INSTRUMENT PANEL UNDER TRAY Installation
33. INSTALL FRONT CONSOLE BOX Installation
34. CONNECT AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY Installation
35. CONNECT AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY Installation
36. CONNECT DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY Installation
37. INSTALL AIR CONDITIONING PANEL ASSEMBLY Installation
38. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY Installation
39. INSTALL CONSOLE BOX CARPET Installation
40. INSTALL REAR CONSOLE BOX COVER Installation
41. INSTALL UPPER CONSOLE PANEL Installation
42. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Installation
43. INSTALL COWL SIDE TRIM BOARD RH Installation
44. INSTALL COWL SIDE TRIM BOARD LH Installation
45. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
46. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
47. INSTALL FRONT DOOR SCUFF PLATE RH Installation
48. INSTALL FRONT DOOR SCUFF PLATE LH Installation
49. INSTALL UPPER INSTRUMENT PANEL Installation
50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation
51. INSTALL INSTRUMENT CLUSTER FINISH PANEL RETAINER Installation
52. INSTALL INSTRUMENT CLUSTER FINISH CENTER PANEL SUB-ASSEMBLY Installation
53. INSTALL COMBINATION METER ASSEMBLY Installation
54. INSTALL INSTRUMENT CLUSTER FINISH PANEL Installation
55. INSTALL FRONT PILLAR GARNISH RH Installation
56. INSTALL FRONT PILLAR GARNISH LH Installation
57. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH Installation
58. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation

59. CONNECT HEATER WATER HOSE INLET A
(a) Install the heater water inlet hose onto the heater unit.
NOTICE: Perform the installation with the hose clip and mark at the correct angle.

60. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
(a) Install the heater water outlet hose onto the heater unit.
NOTICE: Perform the installation with the hose clip and mark at the correct angle.

61. INSTALL LIQUID TUBE SUB-ASSEMBLY
(a) Remove the vinyl tape from liquid tube and the connecting portion of the unit.
(b) Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the liquid tube.
Compressor oil:
ND-OIL8 or equivalent
(c) Install the O-ring onto the liquid tube.
(d) Connect the liquid tube to the unit.
62. INSTALL SUCTION TUBE SUB-ASSEMBLY
(a) Remove the vinyl tape from the suction tube and the connecting part of the unit.
(b) Apply sufficient compressor oil (ND-OIL8) to a new O-ring and the connecting part of the suction tube.
Compressor oil:
ND-OIL8 or equivalent
(c) Install the O-ring onto the suction tube.

(d) Turn the hook connector in the direction indicated by the arrow in the illustration.
(e) Insert the pipe joints securely into the fitting holes and tighten the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
63. INSTALL OUTER COWL TOP PANEL Installation
64. INSTALL FRONT AIR SHUTTER SEAL RH Installation
65. INSTALL FRONT WIPER MOTOR AND LINK Installation
66. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
67. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
68. INSTALL HOOD TO COWL TOP SEAL Installation
69. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
70. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
71. INSTALL FRONT WIPER ARM HEAD CAP Installation
72. ADD ENGINE COOLANT Service and Repair
73. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
74. INSPECT SRS WARNING LIGHT
Diagnosis System
75. CHARGE REFRIGERANT Service and Repair
76. WARM UP ENGINE Service and Repair
77. INSPECT FOR COOLANT LEAK Testing and Inspection
78. INSPECT FOR REFRIGERANT LEAK Service and Repair
79. POSITION FRONT WHEELS FACING STRAIGHT AHEAD