Repair Procedure - Install Interior Parts - Steps 1 - 15

Install interior parts:






1. Install the NEW and improved cooler expansion valve.
A. Apply tape to the improved cooler expansion valve.

Tape: Piping Insulator (P/N: 88578-35170)

NOTE:
Do NOT allow tape to protrude over the sides of the improved cooler expansion valve, or a leak could occur.

B. Apply compressor oil to the two (2) O-rings on the evaporator lines and the fitting surface of the improved cooler expansion valve.

Compressor oil: ND-OIL 8 or equivalent






C. Install the improved cooler expansion valve to the cooler evaporator sub-assembly No. 1 using NEW upper side and lower side O-rings.

Upper Side: P/N 90099-14121
Lower Side: P/N 90099-14120

2. Install the air conditioning tube.






A. Apply compressor oil to two (2) NEW O-rings and the fitting surface of the air conditioning tube assembly.

Compressor oil: ND-OIL 8 or equivalent

B. Install the 2 O-rings on the air conditioning tube assembly.
C. Using a 4 mm hexagon wrench, install the air conditioning tube assembly with the 2 bolts and NEW upper side and lower side O-rings.

Torque: 3.5 N-m (35 kgf-cm, 30 in.-lbs)
Upper Side: P/N 90099-14121
Lower Side: P/N 90099-14120






3. Install the cover plate (expansion valve cover).
A. Install the claw fitting.
B. Install the screw.

CAUTION:
If the hook portion of the upper cover plate is broken during removal, replace the broken hook portion with a NEW on. If the claw is NOT broken, it may be reused.






4. Install the blower assembly.
A. Install the blower assembly with the claw fittings.
a. Slide the blower assembly.
b. Lower down the blower assembly.






B. Install the bolt, the 2 screws and the nut.

Bolt Torque: 9.8 N-m (100 kgf-cm, 87 in.-lbf)
Nut Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)

CAUTION:
- Do NOT reuse the broken bolts.
- Be sure to install hardware to secure the air box.






C. Install the 7 clamps and connect the connectors.

NOTE:
Be sure to connect all connectors.






5. Install the 3 claws fittings and install the air duct No. 2.

HINT:
For easy installation, engage the upper claws first.






6. Install the disc player changer with the bracket (if equipped).
A. Connect the connectors.
B. Engage the 2 claws and place the disc player changer with the bracket temporarily on the body.
C. Install the 4 bolts and disc player changer with the bracket.

Torque: 5 N-m (55 kgf-cm, in.-lbf)






7. Install the glove compartment door assembly.
A. Connect the connectors and install the glove compartment door assembly, then engage the 2 clips.
B. Engage the 5 screws.






8. Install instrument panel ornament.

Engage the 4 clips and the glove instrument panel ornament.






9. Install the 4WD ECU and the tire pressure monitor ECU to the instrument panel under cover No. 2 with 2 screws each.






10. Install the instrument panel under cover No. 2.
A. Engage the 3 clips.
B. Install the screw.






11. Install the tube sub-assembly oil cooler.
A. Install the tube sub-assembly oil cooler.
B. Apply the seal from the LH front side.

Tube Sub-assembly Oil Cooler: P/N 32906-60230






12. Install the A/T tube sub-assembly oil cooler.
A. Insert the hose to the back of the spool.
B. Install the hose so that the paint colors of the subtube and hose match.
C. Install the securing clip to the previous location.
D. After installing the oil cooler tube, add an additional 5 cc to 10 cc of A/T oil to the transmission.






13. Install the A/T oil cooler by tightening all three (3) bolts as shown in the illustration.

Torque: 5.0 N-m (51 kgf-cm, 44 in.-lbf)






14. Prepare the headlamp hole seal RH.

Before November 2004 production:

A. Using Seal, Radiator Side RH (P/N: 53285-60080) as a template, locate the reference nut shown in the illustration.
B. Align the seal to the headlamp hole area.
C. Using the seal as a template, center punch the three (3) locations shown in the illustration.
D. Drill three (3) 7 mm (0.28 in.) holes in the punch locations shown in the illustration.






From December 2004 to January 2006 production:

A. Removed the air shield plate (DO NOT REUSE) from the RH headlamp area






B. Using Seal, Radiator Side RH (P/N: 53285-60080) as a template, locate the reference nut shown in the illustration.
C. Align the seal to the headlamp hole area.
D. Using the seal as a template, center punch one (1) hole at the position shown in the illustration
E. Drill one (1) 7 mm (0.28 in.) hole in the punch location position shown in the illustration.






15. Using the clip, install the Seal, Radiator Side RH.

Seal, Radiator Side RH: P/N 53285-60080