INSTALLATION

CAUTION / NOTICE / HINT

HINT:

A bolt without a torque specification is shown in the standard bolt chart.

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PROCEDURE

1. INSTALL COOLER UNIT DRAIN HOSE GROMMET

Perform this procedure only when removal/installation of the cooler unit drain hose grommet is necessary.

NOTICE:

After removing the cooler unit drain hose grommet, replace it with a new one to prevent water from entering.

(a) Attach one side of the lip on a new cooler unit drain hose grommet (approximately 1/3 of the circumference) to the body hole (fit it to the hole).

*a Lip Penetrate Area

(b) Press the entire upper surface of the rib on the cooler unit drain hose grommet, and fit the entire circumference of the lip to the hole.

Rib Upper Surface

2. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for TMC Made)

HINT:

Perform this procedure only when removal/installation of the No. 1 air duct sub-assembly is necessary.

(a) Install the No. 1 air duct sub-assembly with the 2 nuts in the order shown in the illustration. Torque: 9.8 N·m {100 kgf·cm, 87 in·lbf} NOTICE: Make sure there are no cracks in the No. 1 air duct sub-assembly. Make sure no foreign matter, such as the dash panel insulator, is trapped between the cowl and seal packing. Make sure that the seal packing is securely attached to the cowl on the body. Look from the engine compartment and check that it does not drop down into the fresh air vent. (If foreign matter, such as the dash panel insulator, is trapped or if the seal packing is not securely attached, water or air from gaps may enter the interior.)

3. INSTALL NO. 3 AIR DUCT SUB-ASSEMBLY (for TMMC Made)

4. INSTALL AIR CONDITIONING UNIT ASSEMBLY

(a) Temporarily set the air conditioning unit assembly nearby the position where it is to be installed.

When carrying the air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts.

(b) Temporarily install the air conditioning unit assembly to the instrument panel reinforcement assembly with the 3 bolts.

5. INSTALL ID CODE BOX (IMMOBILIZER CODE ECU) (w/ ID Code Box)

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6. INSTALL TRANSPONDER KEY ECU (IMMOBILIZER CODE ECU) (w/ Transponder ECU)

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7. CONNECT INSTRUMENT PANEL WIRE

(a) Attach the clamp.

(b) Connect the connector.

8. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY

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9. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY

(a) Install the instrument panel reinforcement assembly with air conditioning unit assembly to the guide as shown in the illustration.

When carrying the instrument panel reinforcement assembly with air conditioning unit assembly, hold the bottom of the assembly. Do not hold the following parts.

Install in this Direction

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(b) Temporarily install the 4 bolts (C).

	Bolt (B)		Bolt (C)
	Nut	-	-

(c) Temporarily install the bolt (B).

(d) Temporarily install the 3 bolts (A).

Bolt (A)

(e) Temporarily install the nut.

(f) Tighten the 4 bolts (C).

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(g) Tighten the 3 bolts (A).

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(h) Tighten the bolt (B).

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

10. INSTALL HEATER GROMMET

(a) Install the heater grommet. NOTICE: Push the heater grommet lip seal until it passes over the spools of the heater pipes as shown in the illustration. Make sure that the lip portion of the heater grommet does not sit on top of the spools of the heater pipes. Make sure that there is no gap between the heater grommet and dash panel. Securely fit the heater grommet onto the dash panel. Otherwise, water may enter from the engine room or cause increased noise, vibration or harshness.

*a Spool

11. CONNECT DRAIN COOLER HOSE

NOTICE:

If the cooler unit drain hose grommet was removed from the body, replace it with a new one.

(a) Connect the drain cooler hose to the cooler unit drain hose grommet. NOTICE: When installing the drain cooler hose, make sure it is not twisted or crushed. Otherwise, water may leak into the interior.

(b) Attach the clamp.

12. TEMPORARILY INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Temporarily install the No. 2 instrument panel brace sub-assembly with the bolt, nut and screw.

	Bolt
	Nut
	Screw

13. TEMPORARILY INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Temporarily install the No. 1 instrument panel brace sub-assembly with the bolt, nut and screw.

	Bolt
	Nut
	Screw

14. TIGHTEN INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONING UNIT ASSEMBLY

(a) Tighten the 3 bolts, 2 nuts (A), and 2 screws in the order shown in the illustration.

HINT:

5 and 6 can be done in either order.

Torque:

Bolt :

9.8 N·m {100 kgf·cm, 87 in·lbf}

Nut (A) :

18 N·m {184 kgf·cm, 13 ft·lbf}

	Bolt		Nut (A)
	Nut (B)		Screw

(b) Tighten the nut (B).

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

(c) Tighten the No. 2 instrument panel brace sub-assembly with the bolt. Torque: 20 N·m {204 kgf·cm, 15 ft·lbf}

(d) Tighten the No. 1 instrument panel brace sub-assembly with the bolt. Torque: 20 N·m {204 kgf·cm, 15 ft·lbf}

15. CONNECT INSTRUMENT PANEL WIRE

(a) Attach the clamp.

*a	Clamp	*b	Guide
	Bolt		Connector

(b) Connect the connector.

(c) Attach the guide.

(d) Connect the 2 ground wires with the 2 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

16. INSTALL ECU INTEGRATION BOX RH

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17. CONNECT INSTRUMENT PANEL WIRE

(a) Connect the lever connector.

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*A	for Type A	*B	for Type B
*a	Clamp	*b	Guide
	Bolt		Nut
	Connector		Lever Connector

(b) Attach the clamp.

(c) Connect the connector.

(d) Attach the guide.

(e) Connect the ground wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(f) Install the nut.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(g) Attach the clamp.

(h) Attach the guide.

(i) Connect the 3 ground wires with the 3 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(j) Connect the 2 connectors.

*a Clamp *b Guide

(k) Attach the guide and clamp.

18. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU

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19. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY (for TMC Made)

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20. INSTALL CENTER INSTRUMENT PANEL BRACKET SUB-ASSEMBLY (for TMMC Made)

HINT:

Use the same procedure described as for the No. 3 instrument panel to cowl brace sub-assembly (for TMC Made).

21. INSTALL NO. 2 HEATER TO REGISTER DUCT SUB-ASSEMBLY

(a) Install the No. 2 heater to register duct sub-assembly with the clip.

22. INSTALL NO. 1 CONSOLE BOX DUCT

(a) Install the No. 1 console box duct with the clip.

23. INSTALL REAR NO. 3 AIR DUCT (for TMC Made)

(a) Attach the claw to install the rear No. 3 air duct.

24. INSTALL REAR NO. 2 AIR DUCT (for TMMC Made)

HINT:

Use the same procedure described as for the rear No. 3 air duct (for TMC Made).

25. INSTALL REAR NO. 4 AIR DUCT (for TMC Made)

(a) Attach the claw.

(b) Install the rear No. 4 air duct with the clip.

26. INSTALL REAR NO. 4 AIR DUCT (for TMMC Made)

HINT:

Use the same procedure described as for the rear No. 4 air duct (for TMC Made).

27. INSTALL REAR NO. 1 AIR DUCT

HINT:

Use the same procedure described as for the rear No. 3 air duct (for TMC Made).

28. INSTALL REAR NO. 2 AIR DUCT (for TMC Made)

HINT:

Use the same procedure described as for the rear No. 4 air duct (for TMC Made).

29. INSTALL REAR NO. 3 AIR DUCT (for TMMC Made)

HINT:

Use the same procedure described as for the rear No. 4 air duct (for TMC Made).

30. INSTALL NO. 3 DASH PANEL INSULATOR PAD

(a) Attach the guide to install the No. 3 dash panel insulator pad.

31. INSTALL FRONT FLOOR FRONT CARPET ASSEMBLY

(a) Install the front floor front carpet assembly to its original position as shown in the illustration.

Return to Original Position

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(b) Attach the guide.

(c) Install the clip.

(d) Install the front floor front carpet assembly to its original position as shown in the illustration.

Return to Original Position

Fastener

(e) Attach the guide.

(f) Attach each fastener.

(g) Install the clip.

32. INSTALL FRONT FLOOR CAUTION PLATE COVER (w/ Cover)

(a) Attach the 2 clips to install the front floor caution plate cover.

(b) While pressing at the positions shown in the illustration, attach the guide and claw.

Press Position

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33. INSTALL ACCELERATOR PEDAL ASSEMBLY

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34. INSTALL ACCELERATOR PEDAL PAD

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35. INSTALL LOWER CENTER PILLAR GARNISH LH

(a) Install the lower center pillar garnish LH.

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(b) Return the front door opening trim weatherstrip LH to its original position.

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(c) Return the rear door opening trim weatherstrip LH to its original position.

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36. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH

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37. INSTALL REAR DOOR SCUFF PLATE LH

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38. INSTALL LOWER CENTER PILLAR GARNISH RH

HINT:

Use the same procedure described as for the lower center pillar garnish LH.

39. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH

HINT:

Use the same procedure described as for the front seat outer belt assembly LH.

40. INSTALL REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure described as for the rear door scuff plate LH.

41. INSTALL OUTER LAP BELT ANCHOR COVER

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42. INSTALL NAVIGATION ECU WITH BRACKET (w/ Navigation System)

(a) w/o DCM:

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(b) w/ DCM:

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43. INSTALL DCM (TELEPHONE TRANSCEIVER ASSEMBLY) WITH BRACKET (w/ DCM)

(a) w/ Navigation System:

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(b) w/o Navigation System:

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44. INSTALL STEERING COLUMN ASSEMBLY

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45. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY

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46. INSTALL FRONT SEAT ASSEMBLY LH

(a) for Manual Seat:

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(b) for Power Seat:

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47. INSTALL FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.

48. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose as shown in the illustration.

(b) Make sure to install the hose clip within the range shown in the illustration.

49. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose as shown in the illustration.

(b) Make sure to install the hose clip within the range shown in the illustration.

NOTICE:

Make sure that the hose clamps do not contact each other.

50. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/o Sub-cool Accelerator)

(a) Remove the vinyl tape wrapped around the connection of the air conditioning tube and accessory assembly.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

(c) Install the O-ring to the air conditioning tube and accessory assembly.

NOTICE:

Keep the O-ring and O-ring fitting surface free from foreign matter.

(d) Connect the air conditioning tube and accessory assembly.

51. CONNECT SUCTION TUBE SUB-ASSEMBLY B (w/o Sub-cool Accelerator)

(a) Remove the vinyl tape wrapped around the connection of the suction tube sub-assembly B and the suction tube sub-assembly B.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction tube sub-assembly B.

Compressor Oil:

ND-OIL 11 or equivalent

(c) Install the O-ring to the suction tube sub-assembly B.

NOTICE:

Keep the O-ring and O-ring fitting surface free of foreign matter.

(d) Connect the suction tube sub-assembly B.

(e) Rotate the 1-point tightening plate as shown in the illustration.

Rotate in this Direction

(f) Insert the tube joint into the fitting hole securely and install the bolt. Torque: 9.8 N·m {100 kgf·cm, 87 in·lbf}

52. CONNECT NO. 2 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for TMC Made with Sub-cool Accelerator)

(a) Remove the vinyl tape wrapped around the connection of the No. 2 air conditioning tube and accessory assembly and the No. 2 air conditioning tube and accessory assembly.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the No. 2 air conditioning tube and accessory assembly.

Compressor Oil:

ND-OIL 11 or equivalent

(c) Install the 2 O-rings to the No. 2 air conditioning tube and accessory assembly.

NOTICE:

Keep the O-rings and O-ring fitting surfaces free of foreign matter.

(d) Connect the No. 2 air conditioning tube and accessory assembly.

(e) Rotate the 1-point tightening plate as shown in the illustration.

Rotate in this Direction

(f) Insert the tube joint into the fitting hole securely and install the bolt. Torque: 9.8 N·m {100 kgf·cm, 87 in·lbf}

53. CONNECT SUCTION TUBE SUB-ASSEMBLY B (for TMMC Made with Sub-cool Accelerator)

HINT:

Use the same procedure described as for the No. 2 air conditioning tube and accessory assembly (for TMC Made with Sub-cool Accelerator).

54. INSTALL HOLE PLUG

(a) Install the 2 hole plugs.

55. INSTALL COWL VENTILATOR PANEL SUB-ASSEMBLY

(a) Install the cowl ventilator panel sub-assembly with the 4 bolts and 4 nuts.

Torque:

Bolt :

5.5 N·m {56 kgf·cm, 49 in·lbf}

Nut :

21 N·m {214 kgf·cm, 15 ft·lbf}

Bolt

Nut

(b) Attach the clamp.

(c) w/ Windshield Deicer System:

(1) Attach the clamp.

56. INSTALL COWL VENTILATOR SPLASH SHIELD (for TMC Made)

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57. INSTALL COWL VENTILATOR SPLASH SHIELD (for TMMC Made)

HINT:

Use the same procedure described as for the cowl ventilator splash shield (for TMC Made).

58. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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59. ADD ENGINE COOLANT (for Engine)

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60. INSPECT FOR COOLANT LEAK (for Engine)

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61. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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62. WARM UP COMPRESSOR

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63. INSPECT FOR REFRIGERANT LEAK

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64. CONNECT SUCTION TUBE SUB-ASSEMBLY B (for TMMC Made with Sub-cool Accelerator)

HINT:

Use the same procedure described as for the No. 2 air conditioning tube and accessory assembly (for TMC Made with Sub-cool Accelerator).