Installation

IMPORTANT: First fix all loose parts, for instance electrical cables and air ducts so that they will not rattle.

1. Ensure that all washers are placed in their original positions on the steering column assembly securing bolts and then locate the steering column assembly in its position on the bulk-head partition.
a. Fit the vacuum hose to the steering column assembly. Pull up the wiring loom on the righthand side of the steering column assembly and fit a cable tie to the steering column assembly.
b. Fit the lower nuts securing the steering column assembly and tighten all four nuts.
Tightening torques: 23 Nm (17 ft. lbs.)
Waxed nuts (green chrome plated): 18 Nm (13 ft. lbs.)
2. Tighten the three securing nuts to the wiper motor bracket and fit the link arm. (On older models the link arm is pressed unto the left wiper spindle and the grooved surface is held tight.)
3. Place the electrical leads in position.
a. Replace the LH engine control module (ECM).
b. Fit the ABS electronic control module bracket.
c. Place the ABS electronic control module in position and fit the clips to secure the ABS electronic control module.
4. Replace the caps over the bulk head partition space.
5. Adjust the play between the upper intermediate universal joint and the steering column assembly. Pull out the steering column assembly universal joint fitting.
Tightening torques: 28 Nm (21 ft. lbs.)
6. Fit the electronic carrier to the steering column assembly.
7. Fit the wiring loom bracket. Ensure that the plastic cover is in the right position so that it covers the whole plate bracket.





8. Position the wiring in the correct position.
9. Connect the connector to the ignition switch.
10. Fit the safety cable.
Tightening torques: 1.2 Nm (0.9 ft. lbs.)





11. Fit the defroster vent for the windscreen on the driver side.
12. Fit the inner part of the side air duct on the driver side. Note the clips.
13. Fit the side air duct on the driver side. Fit the air passage. Secure them with cable ties.
14. Place the wiring in the correct position, pull up the turbo charger gauge hose on the left side of the steering column assembly and secure with tape.
a. Lift the facia into position. To make the fitting easier, get a co-worker to assist.
b. Ensure the facia slips into the grooves in the guide lug.
c. Tighten the retaining screws. Replace all plastic caps over the cables.
d. Attach the safety cable to the panel with a cable tie.
15. Place the combined instrument with its glass against the windscreen and connect all connections. Turn the instrument and fit the rubber supports.
16. Place instrument in position in the facia. Fit the turbo charger gauge hose and the two securing bolts.





17. Tighten the side defroster air ducts on the facia.
18. Take away the outer interior air damper from the instrument plate and fit it to the air passage.
a. Fit the central interior air damper.
b. Place the instrument plate in position. Push together the connectors to the switches. Fit the air dampers to the facia plate using a piece of bent steel wire.
c. Fasten the instrument plate and the cover plate over the gear-lever housing with screws.
d. Fit the gear lever gaiter.
19. Re-connect the connectors to the switches. Fit the switches and covers.
20. Cars with air conditioning, replace the inner temperature sensor and fit the covering clips.
21. Connect the connector to the clock/SCC (DCC) unit. Fit the clock/SCC (DCC) unit.
22. Connect and install the ACC control module and clip the cable. For cars with manual air conditioning, refer to Heating and Air Conditioning.
23. Cars for the USA market, position the lower radio compartment. Connect the antenna cable and electrical connections to the upper radio compartment and fit the compartment.
24. Connect both the ash tray lighting and the cigar lighter connectors and fit the ash tray bracket. Put the ash tray in.





25. Fit the dip switch bracket. Pay attention to the adjustment of the horizontal position of the bracket.
26. Fit the control for the windscreen wipers and washers to the dip switch bracket and connect the connector. Fit the control for the direction indicators and headlight dip switch and connect the connector.
27. Fasten up the windscreen wipers and washer cables with a cable tie to the ignition switch housing.





28. Refit the electrical distribution box.
29. Cars with anti-theft alarms, fit the theft alarm control module to the facia. The control module is located to the right under the electrical distribution box.
3O. Take out the interior air damper from the glove compartment and fit the damper to the air duct.
31. Connect the cables to the glove compartments lighting and switch.
32. Pull the interior air dampers into position using a piece of bent steel wire.
33. Fit the floor ducts under the facia on both left and righthand sides.
34. Mount the carpeted panels against the centre console. Guide the edges into the groove on the centre console and then fit the clips.
35. Fit the safety cable and the upper part of the facia.
Tightening torques, safety cable: 28 Nm (21 ft. lbs.)

NOTE:
^ Left side: Where appropriate, connect the connector for the theft alarm LED, fit the spacer and speaker grill.
^ Right side: Where appropriate, connect the sun sensor, fit the spacer and speaker grill.
^ Note the sun sensor location, in the middle of the upper part of the facia.

36. Fit the A pillar trim.





37. Attach the connector and cables the steering column assembly with a cable tie.
38. Fit the upper and then the lower steering wheel caps (4 screws).
39. Fit the steering wheel.
4O. Connect the battery cable.
41. Fit the scuff plate. Fit the left and right acoustic insulation.