Installation

AIR CONDITIONING: AIR CONDITIONING UNIT: 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)

(c) Connect the connectors and install the wire harness.





(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