INSTALLATION

PROCEDURE

1. TEMPORARILY INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Engage the 2 claws.

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

2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY

(a) Engage the 2 guides and claw to connect the ID code box (immobiliser code ECU) as shown in the illustration.

Install in this Direction

(b) Connect each connector.

Install in this Direction

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(c) Engage each clamp.

(d) Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly as shown in the illustration.

(e) Install the 4 bolts (A).

*A	for Manual Transaxle	-	-
	Bolt (A)		Bolt (B)
	Bolt (C)		Nut

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(f) Install the bolt (B).

Torque:

23.6 N·m {241 kgf·cm, 17 ft·lbf}

(g) for Manual Transaxle:

(1) Install the bolt (C).

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

(h) Temporarily install the nut.

(i) Install the 2 bolts.

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(j) Install a new cooler unit drain hose grommet. NOTICE: If the drain cooler hose is disconnected from the cooler unit drain hose grommet, make sure to replace the cooler unit drain hose grommet with a new one. Failure to do so may lead to water ingress. Make sure that the entire lip of the cooler unit drain hose grommet is securely engaged to the vehicle body.

*a Lip

(k) Connect the drain cooler hose.

(l) Install the front floor mat to its original position as shown in the illustration.

3. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the No. 2 instrument panel brace sub-assembly with the bolt and nut.

Torque:

Bolt :

20 N·m {204 kgf·cm, 15 ft·lbf}

Nut :

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(c) Engage each clamp.

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

Move in this Direction

4. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

(a) Install the No. 1 instrument panel brace sub-assembly with the bolt and nut.

Torque:

Bolt :

20 N·m {204 kgf·cm, 15 ft·lbf}

Nut :

18 N·m {184 kgf·cm, 13 ft·lbf}

(b) Temporarily install the screw.

HINT:

Do not fully tighten the screw.

(c) Engage each clamp.

(d) Connect the earth wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(e) Install the front floor mat to its original position as shown in the illustration.

Move in this Direction

5. INSTALL AIR CONDITIONER UNIT ASSEMBLY

(a) Tighten the 3 bolts, 2 screws and nut to install the air conditioner unit assembly.

	Bolt		Screw
	Nut	-	-

Torque:

Bolt :

9.8 N·m {100 kgf·cm, 87 in·lbf}

Nut :

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

Tighten the bolts, screws and nut in the order shown in the illustration.

6. CONNECT INSTRUMENT PANEL WIRE

(a) Engage each clamp.

*a	Lock Lever
	Move in this Direction

(b) Temporarily connect the connector and then move the lock lever as shown in the illustration to securely connect the connector.

NOTICE:

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

(c) Check that there is no looseness in the installed parts of the airbag sensor assembly.

(d) Engage each clamp.

(e) Connect the instrument panel wire with the screw.

Torque:

3.2 N·m {33 kgf·cm, 28 in·lbf}

(f) Connect the 3 earth wires with the 3 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(g) w/ PTC Heater:

(1) Connect the earth wire with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(h) Connect each connector.

(i) Connect the instrument panel wire with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(j) Connect the relay block holder with the 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

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

Click here

8. INSTALL NO. 3 INSTRUMENT PANEL TO COWL BRACE SUB-ASSEMBLY

(a) Install the No. 3 instrument panel to cowl brace sub-assembly with the bolt and nut.

Torque:

Bolt :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut :

6.0 N·m {61 kgf·cm, 53 in·lbf}

9. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY

(a) Engage the guide and 6 claws to install the lower defroster nozzle assembly.

10. INSTALL CENTER HEATER TO REGISTER DUCT SUB-ASSEMBLY

(a) Install the center heater to register duct sub-assembly with the 2 clips.

(b) Engage the clamp.

11. INSTALL NO. 3 DASH PANEL INSULATOR PAD

(a) Install the No. 3 dash panel insulator pad with 2 new clips as shown in the illustration.

12. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 4 claws to install the rear No. 2 air duct as shown in the illustration.

Install in this Direction

13. INSTALL REAR NO. 5 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 2 claws to install the rear No. 5 air duct as shown in the illustration.

Install in this Direction

14. INSTALL REAR NO. 6 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 2 claws to install the rear No. 6 air duct as shown in the illustration.

Install in this Direction

15. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct)

Install in this Direction

(a) Engage the 2 claws to install the rear No. 3 air duct as shown in the illustration.

16. INSTALL REAR NO. 4 AIR DUCT (w/ Rear Air Duct)

(a) Engage the 2 claws to install the rear No. 4 air duct as shown in the illustration.

Install in this Direction

17. CONNECT FRONT FLOOR CARPET ASSEMBLY

(a) for LH Side: (1) Install the front floor carpet assembly to its original position as shown in the illustration. (2) Engage the 2 guides. (3) Install the 3 front floor carpet clips.

(b) for RH Side: (1) Install the front floor carpet assembly to its original position as shown in the illustration. (2) Engage the 2 guides. (3) Install the 3 front floor carpet clips.

18. INSTALL FRONT FLOOR CAUTION PLATE COVER

(a) Engage the guide and claw to install the front floor caution plate cover as shown in the illustration.

	Install in this Direction (1)
	Install in this Direction (2)

19. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY (for Sedan)

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20. INSTALL FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY (for Hatchback)

Click here

21. INSTALL COOLER (ROOM TEMP. SENSOR) THERMISTOR (for Automatic Air Conditioning System)

(a) Connect the aspirator and connector to install the cooler (room temp. sensor) thermistor.

22. INSTALL METER MIRROR SUB-ASSEMBLY (w/ Headup Display)

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23. INSTALL ECU INTEGRATION BOX RH

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24. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

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25. INSTALL STEERING COLUMN ASSEMBLY

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26. INSTALL FRONT SEAT ASSEMBLY LH

for Manual Seat:

Click here

for Power Seat:

Click here

27. INSTALL FRONT SEAT ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

28. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/ Sub-cool Accelerator)

(a) Remove the vinyl tape from the suction pipe sub-assembly.

(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surfaces of the suction pipe sub-assembly.

Compressor Oil:

ND-OIL 12 or equivalent

(c) Install the 2 O-rings to the suction pipe sub-assembly.

NOTICE:

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

(d) Connect the suction pipe sub-assembly.

(e) Rotate the hook connector as shown in the illustration.

(f) Insert the tube joint into the fitting hole securely and temporarily install the bolt.

(g) Using a union nut wrench, tighten the bolt. Torque: Specified tightening torque : 9.8 N·m {100 kgf·cm, 87 in·lbf} HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.6 N*m (88 kgf*cm, 76 in.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

29. CONNECT COOLER REFRIGERANT LIQUID PIPE A (w/o Sub-cool Accelerator)

(a) Remove the vinyl tape from the cooler refrigerant liquid pipe A.

(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe A.

(c) Install the O-ring to the cooler refrigerant liquid pipe A.

NOTICE:

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

(d) Connect the cooler refrigerant liquid pipe A.

30. CONNECT SUCTION PIPE SUB-ASSEMBLY (w/o Sub-cool Accelerator)

(a) Remove the vinyl tape from the suction pipe sub-assembly.

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

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

NOTICE:

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

(d) Connect the suction pipe sub-assembly.

(e) Rotate the hook connector as shown in the illustration.

(f) Insert the tube joint into the fitting hole securely and temporarily install the bolt.

(g) Using a union nut wrench, tighten the bolt. Torque: Specified tightening torque : 9.8 N·m {100 kgf·cm, 87 in·lbf} HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.6 N*m (88 kgf*cm, 76 in.*lbf)

*a Torque Wrench Fulcrum Length *b Union Nut Wrench

31. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration. NOTICE: Do not apply excessive force to the inlet heater water hose.

*a View A *b for M20A-FKS: Marking (Green) for 2ZR-FAE: Marking (White) for 2ZR-FXE: Marking (Brown) *c Clip Installation Angle (90°) *d Clip Installation Angle (120°)

32. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose with the marking facing up and engage the clip within the area shown in the illustration. NOTICE: Do not apply excessive force to the outlet heater water hose.

*a View A *b for M20A-FKS: Marking (Green) for 2ZR-FAE: Marking (White) for 2ZR-FXE: Marking (Red) *c Clip Installation Angle (90°) *d Clip Installation Angle (120°)

33. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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34. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

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35. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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36. ADD ENGINE COOLANT

for M20A-FKS: Click here

for 2ZR-FAE: Click here

for 2ZR-FXE: Click here

37. INSPECT FOR COOLANT LEAK

for M20A-FKS: Click here

for 2ZR-FAE: Click here

for 2ZR-FXE: Click here

38. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))

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39. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFO-1234yf(R1234yf))

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40. WARM UP ENGINE (for Gasoline Model)

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41. WARM UP COMPRESSOR (for HV Model)

for HFC-134a(R134a): Click here

for HFO-1234yf(R1234yf): Click here

42. INSPECT FOR REFRIGERANT LEAK (for HFC-134a(R134a))

Click here

43. INSPECT FOR REFRIGERANT LEAK (for HFO-1234yf(R1234yf))

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