Air Conditioning Unit Installation

Install the blower assembly with the claw and screw.

Torque:

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

Connect the connector.

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

Install the No. 2 air duct with the screw.

Torque:

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

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

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}(bolt 1)

Driver seat side:

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

Passenger seat side:

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

   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}

Install the instrument panel reinforcement with the 4 bolts and nut.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}(nut 1)

Install the bolt and cap.

Connect the 19 connectors and attach the 27 clamps.

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

Attach the 4 claws to install the defroster nozzle lower.

Install the steering column assembly with the 4 nuts.

Torque:

21 N*m{214 kgf*cm, 16 ft.*lbf}

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

Install the clamp to the steering column hole shield.

Install the brake pedal return spring.

Install the steering column assembly with the 4 nuts.

Torque:

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

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

Install the clamp to the steering column hole shield.

Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering sliding yoke sub-assembly.

Temporarily install the bolt.

NOTICE:

Do not tighten the bolt.

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

Install bolt (A) and tighten the 2 bolts.

Torque:

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

Engage the 5 claws.

NOTICE:

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

Engage the 2 clamps.

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

Torque:

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

Install the 6 bolts <D> and nut <H>.

Engage the 2 claws and install the cooler thermistor.

Engage the clamps.

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

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

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

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

Connect the connector.

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

HINT:

Install the bolts in the order shown in the illustration.

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

Connect the connector.

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

Connect the connector.

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

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

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

Connect the connectors.

Engage the 2 claws.

Install the glove compartment door assembly with the 5 screws.

Connect the connector.

NOTICE:

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

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

Torque:

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

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

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

Engage the 6 claws and install the front door opening trim cover RH.

Connect the connectors.

Engage the 2 pins.

Engage the 2 claws and install the combination meter assembly.

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

Connect the connector.

NOTICE:

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

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

Torque:

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

Connect the connectors.

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

Connect the connectors.

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

Engage the 2 claws.

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

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

Engage the 6 claws and install the front door opening trim cover LH.

Engage the 4 clips.

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

Connect the connector.

Engage the 4 clips.

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

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

Engage the claw to install the upper steering column cover.

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

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

Install the 2 screws.

Torque:

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

Engage the claw to install the steering column cover upper.

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

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

NOTICE:

Do not damage the tilt and telescopic switch.

Install the 3 screws.

Torque:

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

Check that the engine switch is off.

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

CAUTION:

After removing the terminal, wait for at least 90 seconds before starting the operation.

Rotate the spiral cable with steering sensor counterclockwise slowly by hand until it feels firm.

NOTICE:

Do not turn the spiral cable with steering sensor by the airbag wire harness.

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

NOTICE:

Do not turn the spiral cable with spiral sensor by the airbag wire harness.

HINT:

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

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

Install the steering wheel assembly set nut.

Torque:

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

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

Connect the 2 connectors to the steering pad.

NOTICE:

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

Connect the horn connector.

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

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

Torque:

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

Install the steering wheel No.3 cover lower.

Install the steering wheel No.2 cover lower.

Connect each connector.

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

Connect each connector.

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

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

Connect the connectors.

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

Engage the 2 claws and 2 clips.

Install the 2 bolts <C>.

Install the 2 bolts <C>.

Connect the connector.

Connect the connectors.

Engage the 2 clamps.

Install the 2 bolts <C>.

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

Install the rear ash receptacle assembly.

Connect the connectors.

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

Install the front ash receptacle sub-assembly with the 2 screws <F>.

Engage the 6 clips.

Close the snap.

Engage the 7 claws and 2 clips.

Close the snap.

Connect the connectors.

Engage the 8 clips and install the console panel sub-assembly.

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

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

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

Torque:

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

Connect the 2 connectors.

Engage the 11 claws.

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

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

Clean the wiper arm serrations.

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

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

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

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

Clean the wiper arm serrations.

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

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

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

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.

Install the front wiper arm head cap.

HINT:

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

Engage the claw and the 3 clips, then install the front upper fender protector LH.

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

Install the water hose and attach the clip.

Use the same procedures described for the water hose inlet.

Remove the vinyl tape attached to the tube.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid tube.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring on the liquid tube.

Install the liquid tube to the fitting hole.

Remove the vinyl tape attached to the pipe.

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

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring on the suction pipe.

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

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

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:

430 +- 30 g (15.17 +- 1.06 oz.)

SST

07110-58060(07117-58060,07117-58070,07117-58080,07117-58090,07117-78050,07117-88060,07117-88070,07117-88080)

NOTICE:

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

1. 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.
   

Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant.

NOTICE:

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.

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

Perform the operation under the following conditions:

1. Stop the engine.
   

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

1. Repeat the test 2 or 3 times.
   

1. 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)
   

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

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.

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.

Install the side cover with the 5 clips.

Install the side cover with the 2 clips.

Install the intake duct seal with the 11 clips.