A bolt without a torque specification is shown in the standard bolt chart.
88539D
1.INSTALL COOLER UNIT DRAIN PIPE
Perform this procedure only when removal/installation of the cooler unit drain pipe is necessary.
Install the piping clamp with 2 screws.
88539C
2.INSTALL NO. 2 COOLER UNIT DRAIN HOSE
Perform this procedure only when removal/installation of the No. 2 cooler unit drain hose is necessary.
Install the No. 2 cooler unit drain hose to cooler unit drain pipe.
Temporarily install the cooler unit drain pipe with No. 2 cooler unit drain hose.
Install the cooler unit drain pipe with No. 2 cooler unit drain hose with the bolt and attach the clamp.
88539
3.INSTALL NO. 1 COOLER UNIT DRAIN HOSE
After removing the No. 1 cooler unit drain hose, replace it with a new one to prevent water from entering.
| *a | Marking |
|
Install in this Direction |
Install the No. 1 cooler unit drain hose.
Install the No. 1 cooler unit drain hose with its paint mark facing upward.
Connect the No. 1 cooler unit drain hose to cooler unit drain pipe.
51405A
4.INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
Perform this procedure only when removal/installation of the No. 1 cooler unit drain hose and No. 2 cooler unit drain hose is necessary.
52618
5.INSTALL LOWER FRONT BUMPER ABSORBER
Perform this procedure only when removal/installation of the No. 1 cooler unit drain hose and No. 2 cooler unit drain hose is necessary.
51406A
6.INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (w/ No. 2 Engine Under Cover Sub-assembly)
Perform this procedure only when removal/installation of the No. 1 cooler unit drain hose and No. 2 cooler unit drain hose is necessary.
7.INSTALL AIR CONDITIONER UNIT ASSEMBLY
Be sure to support the air conditioning unit assembly when installing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
When installing the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
Be careful not to damage the internal components of the instrument panel reinforcement assembly and air conditioning unit assembly on the glass etc. Only perform installation after first taking the appropriate actions.
Do not allow the air conditioning unit assembly to strike the airbag ECU assembly. Doing so may damage the heater case, causing water leaks.
Temporarily install the air conditioner unit assembly to the instrument panel reinforcement assembly with the 4 bolts.
Do not hold the air conditioning harness assembly. Otherwise, static electricity from the technician may damage the air conditioning harness assembly.
Do not hold the heater core or pipe of the heater radiator unit sub-assembly. Otherwise, the pipe may detach, the clamp may be damaged, or the crimped areas of the heater core and pipe of the heater radiator unit sub-assembly may be damaged, causing coolant to leak.
Do not hold the air conditioning radiator damper servo sub-assembly, blower damper servo sub-assembly or link. Otherwise, the servo motor may become misaligned, causing abnormal operation noise, temperature control defects, or air leaks due to sealing defects in the doors.
Do not hold the door. Doing so may cause air leaks due to closing defects resulting from excessive opening/closing. Also, keep the door free from oil and grease.
8.INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY WITH AIR CONDITIONER UNIT ASSEMBLY
Be sure to support the air conditioning unit assembly when installing it because failure to do so may cause the bracket of the air conditioning unit assembly to break.
When installing the air conditioning unit assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged.
Be careful not to damage the internal components of the instrument panel reinforcement assembly with air conditioning unit assembly on the glass etc. Only perform installation after first taking the appropriate actions.
Temporarily install the instrument panel reinforcement assembly with air conditioner unit assembly.
Do not allow the heater radiator unit sub-assembly heater pipe or cooler expansion valve to strike the body.
Make sure that both parts are securely installed to the guide.
for Automatic Transmission:
Install the instrument panel reinforcement assembly with the 8 bolts.
| *A | for Manual Transmission | - | - |
| *a | Engine Room Side | - | - |
|
Bolt A |
|
Bolt B |
for Manual Transmission:
Install the instrument panel reinforcement assembly with the 9 bolts.
| *a | Standard Position |
| *b | Hose Notch |
| *c | Rib |
Align the standard position, install the drain cooler hose.
Tighten the nut.
88650N
9.INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
55306A
10.INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
|
Bolt |
|
Nut |
Install the No. 1 instrument panel brace sub-assembly with the 3 bolts and 2 nuts.
55307C
11.INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY
|
Bolt |
|
Nut |
|
Screw |
Install the No. 2 instrument panel brace sub-assembly with the 2 bolts.
Install the nut and screw.
12.INSTALL AIR CONDITIONER UNIT ASSEMBLY
Tighten the 4 bolts in the order shown in the illustration.
| *a | Bolt(A) | - | - |
87201A
13.INSTALL AIR DUCT SUB-ASSEMBLY
Temporarily install the air duct sub-assembly.
Tighten the 2 nuts.
55950G
14.INSTALL DEFROSTER NOZZLE ASSEMBLY
Attach the claw to install the defroster nozzle assembly.
82141
15.INSTALL INSTRUMENT PANEL WIRE
Connect each connector and attach each clamp and install the instrument panel wire.
| *A | w/ PTC Heater | - | - |
| *1 | Ground Wire | *2 | Protector Cover |
|
Connector |
|
Bolt |
|
Nut |
|
Install in this Direction |
Install each nut.
Attach the claw and install the protector cover together with the instrument panel wire.
Attach the claw and close protector cover.
Install each bolt and each ground wire.
58193G
16.INSTALL NO. 3 FRONT FLOOR FOOTREST
Attach the clip to install the No. 3 front floor footrest.
58510D
17.INSTALL FRONT FLOOR CARPET ASSEMBLY
w/ Console Box:
Install the front floor carpet assembly to the original position as shown in the illustration.
|
Install in this Direction |
|
Fastener |
Attach each fastener.
Install the 4 clips.
w/o Console Box:
Install the front floor carpet assembly to the original position as shown in the illustration.
|
Install in this Direction |
|
Fastener |
Attach each fastener.
Install the 4 clips.
62520B
18.INSTALL QUARTER TRIM PANEL ASSEMBLY LH (for 4 Door)
62620K
19.INSTALL SIDE TRIM BOARD ASSEMBLY LH (for High Roof)
62640M
20.INSTALL REAR QUARTER TRIM BOARD ASSEMBLY LH (for 4 Door)
58777A
21.INSTALL TOOL BAG HOLDER (for 4 Door)
73570B
22.INSTALL REAR SEAT OUTER BELT ASSEMBLY (FLOOR ANCHOR) (for 4 Door, w/ Seat Belt)
67935
23.INSTALL BACK DOOR SCUFF PLATE (for 4 Door)
62414A
24.INSTALL LOWER CENTER PILLAR GARNISH LH (for 5 Door)
Use the same procedure described for the RH side.
67918D
25.INSTALL REAR DOOR SCUFF PLATE LH (for 5 Door)
Use the same procedure described for the RH side.
62413A
26.INSTALL LOWER CENTER PILLAR GARNISH RH
74680
27.INSTALL PILLAR ASSIST GRIP ASSEMBLY B (w/ Assist Grip)
74617A
28.INSTALL ASSIST GRIP PLUG (w/ Assist Grip)
67917C
29.INSTALL REAR DOOR SCUFF PLATE RH
74707
30.INSTALL NO. 1 HAND GRIP FRAME SUB-ASSEMBLY (for Semi-trim, w/ Hand Rail)
74733
31.INSTALL NO. 1 HAND GRIP COVER (for Semi-trim, w/ Hand Rail)
73220
32.INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH (FLOOR ANCHOR)
73210
33.INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH (FLOOR ANCHOR)
Use the same procedure described for the LH side.
34.INSTALL OUTER LAP BELT ANCHOR COVER
Use the same procedure for the other side.
35.INSTALL TRANSMISSION INSTRUMENT PANEL SHIFT ASSEMBLY (for Automatic Transmission)
33530K
36.INSTALL SHIFT LEVER ASSEMBLY (for Manual Transmission)
45250
37.INSTALL STEERING COLUMN ASSEMBLY
87212F
38.INSTALL REAR NO. 2 AIR DUCT (w/ Rear Foot Duct)
|
Install in this Direction |
Install the rear No. 2 air duct as shown in the illustration.
87212G
39.INSTALL REAR NO. 3 AIR DUCT (w/ Rear Foot Duct)
|
Install in this Direction |
Install the rear No. 3 air duct as shown in the illustration.
87211
40.INSTALL NO. 1 AIR DUCT
Attach the claw to install a new No. 1 air duct.
Install the 2 bolts.
When removing, do not crack or deform the lower heater case of the air conditioning radiator assembly.
If the No. 1 air duct is reused, it may fall off or abnormal noise may occur. Therefore, make sure to replace with a new one.
41.INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY WITH MAIN BODY ECU
89661
42.INSTALL ECM
55301
43.INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
44.INSTALL FRONT SEAT ASSEMBLY
for Power Seat Type:
for Separate Seat Type:
for Fixed Bench Seat Type:
for Sliding Bench Seat Type:
88897M
45.INSTALL HEATER PIPE GROMMET (w/ Heater System)
| *a | Marked Part |
| *b | Spool |
Press the marked parts to attach the claw and install the heater pipe grommet.
Push the heater pipe 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 pipe grommet does not sit on top of the spools of the heater pipes.
Make sure that there is no gap between the heater pipe grommet and dash panel.
Securely fit the heater pipe grommet onto the dash panel. Otherwise, water may enter from the engine room or cause increased noise, vibration or harshness.
87245A
46.CONNECT HEATER WATER HOSE INLET A (w/ Heater System, for 1GD-FTV)
| *1 | Hose Clip |
| *2 | Heater Water Hose Inlet A |
| *a | View A |
| *b | Stopper |
| *c | Marking (White or Blue or Brown) |
| *d | Hose Clip Installation Range (7.5 mm (0.295 in.)) |
| *e | Clip Installation Angle (60°) |
Connect the heater water hose inlet A with the marking facing left and attach the clip within the area shown in the illustration.
Do not apply excessive force to the heater water hose inlet A.
Make sure the heater water hose inlet A is securely inserted to the stopper. However, if the end of the heater water hose inlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
Connect the heater water hose inlet A so that its marking faces the top of the vehicle.
Make sure to install the hose clip within the range shown in the illustration.
Make sure that the hose clamps do not contact each other.
87246A
47.CONNECT HEATER WATER HOSE OUTLET A (w/ Heater System, for 1GD-FTV)
| *1 | Hose Clip |
| *2 | Heater Water Hose Outlet A |
| *a | View A |
| *b | Stopper |
| *c | Marking (White or Brown) |
| *d | Hose Clip Installation Range (7.5 mm (0.295 in.)) |
| *e | Clip Installation Angle (60°) |
Connect the heater water hose outlet A with the marking facing left and attach the clip within the area shown in the illustration.
Do not apply excessive force to the heater water hose outlet A.
Make sure the heater water hose outlet A is securely inserted to the stopper. However, if the end of the heater water hose outlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
Connect the heater water hose outlet A hose so that its marking faces the top of the vehicle.
Make sure to install the hose clip within the range shown in the illustration.
Make sure that the hose clamps do not contact each other.
87246A
48.CONNECT HEATER WATER HOSE OUTLET A (w/ Heater System, for 7GR-FKS)
| *1 | Hose Clip |
| *2 | Heater Water Hose Outlet A |
| *a | View A |
| *b | Stopper |
| *c | Marking (White or Yellow or Pink) |
| *d | Hose Clip Installation Range (7.5 mm (0.295 in.)) |
| *e | Clip Installation Angle (60°) |
Connect the heater water hose outlet A with the marking facing left and attach the clip within the area shown in the illustration.
Do not apply excessive force to the heater water hose outlet A.
Make sure the heater water hose outlet A is securely inserted to the stopper. However, if the end of the heater water hose outlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
Connect the heater water hose outlet A so that its marking faces the top of the vehicle.
Make sure to install the hose clip within the range shown in the illustration.
Make sure that the hose clamps do not contact each other.
87245A
49.CONNECT HEATER WATER HOSE INLET A (w/ Heater System, for 7GR-FKS)
| *1 | Hose Clip |
| *2 | Heater Water Hose inlet A |
| *a | View A |
| *b | Stopper |
| *c | Marking (Yellow or Pink) |
| *d | Hose Clip Installation Range (7.5 mm (0.295 in.)) |
| *e | Clip Installation Angle (60°) |
Connect the heater water hose inlet A with the marking facing left and attach the clip within the area shown in the illustration.
Do not apply excessive force to the heater water hose inlet A.
Make sure the heater water hose inlet A is securely inserted to the stopper. However, if the end of the heater water hose inlet A is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.
Connect the heater water hose inlet A so that its marking faces the top of the vehicle.
Make sure to install the hose clip within the range shown in the illustration.
Make sure that the hose clamps do not contact each other.
88710C
50.CONNECT AIR CONDITIONING TUBE ASSEMBLY (w/ Cooler System, Sub-cool Accelerator)
Remove the vinyl tape wrapped around the connection of the air conditioning tube assembly and the air conditioning tube assembly.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube assembly.
ND-OIL 8 or equivalent
Install the O-ring to the air conditioning tube assembly.
Keep the O-rings and O-ring fitting surfaces free of foreign matter.
Connect the air conditioning tube assembly.
Do not apply excessive force to the air conditioning tube assembly.
Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed).
|
Install in this Direction |
Rotate the 1-point tightening plate as shown in the illustration.
Insert the tube joint into the fitting hole securely and tighten the bolt.
88716A
51.CONNECT COOLER REFRIGERANT LIQUID PIPE A (w/ Cooler System, w/o Sub-cool Accelerator)
Remove the vinyl tape wrapped around the connection of the cooler refrigerant liquid pipe A.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant liquid pipe A.
ND-OIL 8 or equivalent
Install the O-ring to the cooler refrigerant liquid pipe A.
Keep the O-rings and O-ring fitting surfaces free of foreign matter.
Connect the cooler refrigerant liquid pipe A.
Do not apply excessive force to the cooler refrigerant liquid pipe A.
Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed).
88717A
52.CONNECT COOLER REFRIGERANT SUCTION PIPE A (w/ Cooler System, w/o Sub-cool Accelerator)
Remove the vinyl tape wrapped around the connection of the cooler refrigerant suction pipe A.
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler refrigerant suction pipe A.
ND-OIL 8 or equivalent
Install the O-ring to the cooler refrigerant suction pipe A.
Keep the O-rings and O-ring fitting surfaces free of foreign matter.
Connect the cooler refrigerant suction pipe A.
Do not apply excessive force to the cooler refrigerant suction pipe A.
Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed).
|
Install in this Direction |
Rotate the 1-point tightening plate as shown in the illustration.
Insert the pipe joint into the fitting hole securely and tighten the bolt.
55701J
53.INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
55738D
54.INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL
47220D
55.CONNECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY
56.INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
57.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
58. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL
When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.
59.INSPECT WASHER NOZZLE
60.ADD ENGINE COOLANT (w/ Heater System)
61.INSPECT FOR COOLANT LEAK (w/ Heater System)
62. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Cooler System)
63.WARM UP ENGINE (w/ Cooler System)
64.INSPECT FOR REFRIGERANT LEAK (w/ Cooler System)
65. INITIALIZE SERVO MOTOR (for Automatic Air Conditioning System)
66.PERFORM DIAGNOSTIC SYSTEM CHECK
67.CHECK SRS WARNING LIGHT