Air Conditioning Unit

Air Conditioning Unit:

AIR CONDITIONING UNIT

REMOVAL

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
a. Start up the engine.
b. Turn the A/C switch on.
c. Operate the cooler compressor at an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.
d. Stop the engine.
e. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
3. DISCONNECT BATTERY NEGATIVE TERMINAL

NOTE: Wait for 90 seconds after disconnecting the terminal to prevent the airbag from deploying.

4. REMOVE COOL AIR INTAKE DUCT SEAL
5. REMOVE HOOD HINGE COVER (for LH Side)
6. REMOVE HOOD HINGE COVER (for RH Side)
7. REMOVE ENGINE ROOM SIDE COVER LH
8. REMOVE ENGINE ROOM SIDE COVER RH
9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
10. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
11. REMOVE FRONT SUSPENSION UPPER CENTER BRACE
12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
15. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

16. DISCONNECT SUCTION PIPE SUB-ASSEMBLY

a. Remove the bolt, and slide the hook connector.
b. Disconnect the suction pipe sub-assembly.
c. Remove the O-ring from the suction hose sub-assembly.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

17. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY
a. Disconnect the air conditioner tube and accessory.
b. Remove the O-ring from the air conditioner tube and accessory.

NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

18. DISCONNECT HEATER OUTLET WATER HOSE

a. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater outlet water hose.

NOTE:
- Do not apply excessive force to the heater outlet water hose.
- Prepare a drain pan or cloth in case the coolant leaks.

19. DISCONNECT HEATER INLET WATER HOSE

HINT: Disconnection procedure for the heater inlet water hose is the same as that for the heater outlet water hose.

20. REMOVE LOWER NO. 3 STEERING WHEEL COVER
21. REMOVE LOWER NO. 2 STEERING WHEEL COVER
22. REMOVE STEERING PAD
23. REMOVE STEERING WHEEL ASSEMBLY
24. REMOVE FRONT DOOR SCUFF PLATE LH
25. REMOVE FRONT DOOR OPENING TRIM COVER LH
26. REMOVE SIDE INSTRUMENT PANEL LH
27. REMOVE INSTRUMENT PANEL FINISH PANEL END LH
28. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY
29. REMOVE STEERING COLUMN COVER
30. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY
31. REMOVE TILT & TELESCOPIC SWITCH
32. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
33. REMOVE COMBINATION METER ASSEMBLY
34. REMOVE NO. 1 SWITCH HOLE BASE
35. REMOVE INSTRUMENT PANEL FINISH PANEL END RH
36. REMOVE FRONT DOOR SCUFF PLATE RH
37. REMOVE FRONT DOOR OPENING TRIM COVER RH
38. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
39. REMOVE SIDE INSTRUMENT PANEL RH
40. REMOVE FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY
41. REMOVE LOWER INSTRUMENT PANEL RH
42. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY
43. REMOVE UPPER CONSOLE PANEL ASSEMBLY WITH FRONT ASH RECEPTACLE
44. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY
45. REMOVE INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System)
46. REMOVE MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System)
47. REMOVE HEATER SEAT SWITCH CONSOLE BASE (w/o Seat Heater System)
48. REMOVE HEATER SEAT SWITCH CONSOLE BASE (w/ Seat Heater System)
49. REMOVE CONSOLE BOX POCKET
50. REMOVE CONSOLE BOX CARPET
51. REMOVE CONSOLE REAR END PANEL SUB-ASSEMBLY
52. REMOVE REAR CONSOLE BOX ASSEMBLY
53. REMOVE FRONT PILLAR GARNISH LH
54. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
55. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)
56. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY
57. REMOVE FRONT PILLAR GARNISH RH
58. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
59. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)
60. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY
61. REMOVE NO. 1 SPEAKER HOLE COVER
62. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY
63. REMOVE NO. 1 INSTRUMENT PANEL MOUNTING BRACKET
64. REMOVE PUSH START SWITCH
65. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY
66. REMOVE ROOM TEMPERATURE SENSOR
67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (w/o DVD Player)
68. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (w/ DVD Player)

69. REMOVE FLOOR CARPET BRACKET LH

a. Release the 2 claws.
b. Turn back the floor carpet.

c. Remove the 3 clips.
d. Remove the floor carpet bracket LH.

70. REMOVE FLOOR CARPET BRACKET RH

a. Release the 2 claws.
b. Turn back the floor carpet.

c. Remove the 3 clips.
d. Remove the floor carpet bracket RH.

71. REMOVE NO. 2 CONSOLE BOX DUCT

a. Remove the bolt and No. 2 console box duct.

72. REMOVE NO. 3 CONSOLE BOX DUCT

a. Remove the bolt and No. 3 console box duct.

73. REMOVE NO. 1 CONSOLE BOX DUCT

a. Remove the No. 1 console box duct.

74. REMOVE REAR NO. 2 AIR DUCT

a. Release the 2 claws and remove the rear No. 2 air duct.

75. REMOVE REAR NO. 1 AIR DUCT

a. Release the 2 claws and remove the rear No. 1 air duct.

76. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY
77. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
78. REMOVE STEERING COLUMN ASSEMBLY
79. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY

80. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Remove the 24 clamps, disconnect the 11 connectors, and then disconnect the wire harness.

b. Remove the 8 nuts, 7 bolts, and junction block.

c. Remove the cap and bolt from the engine compartment side.
d. Remove the 3 bolts and nut.

e. Using a "TORX" socket wrench (T40), remove the 5 "TORX" bolts.

HINT: The "TORX" bolts on the passenger side can be removed with the collars for adjustment.

f. Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly.

g. Remove the 3 bolts, 2 screws, and instrument panel reinforcement assembly.

INSTALLATION

1. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

a. Install the conditioner unit assembly to the instrument panel reinforcement assembly with the 2 screws and 3 bolts.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

NOTE: Tighten the bolts and screws in the order given in the illustration to install the air conditioner unit assembly.

b. Driver seat:
1. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 3 "TORX" bolts.

Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)

c. Passenger seat:
1. Using a 12 mm hexagon wrench, adjust the position of the 2 collars.

Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)

2. Using a "TORX" socket wrench (T40), install the instrument panel reinforcement assembly with the 2 "TORX" bolts.

Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)

d. Install the instrument panel reinforcement assembly with the 3 bolts and nut.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) (NUT)

e. Install the bolt and cap.
f. Connect the connectors and clamps.

g. Install the 8 nuts and 7 bolts.

2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY
3. INSTALL STEERING COLUMN ASSEMBLY
4. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY
5. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

6. INSTALL REAR NO. 1 AIR DUCT

a. Engage the 2 claws to install the rear No. 1 air duct.

7. INSTALL REAR NO. 2 AIR DUCT

a. Engage the 2 claws to install the rear No. 2 air duct.

8. INSTALL NO. 1 CONSOLE BOX DUCT

a. Install the No. 1 console box duct.

9. INSTALL NO. 3 CONSOLE BOX DUCT

a. Install the bolt and No. 3 console box duct.

10. INSTALL NO. 2 CONSOLE BOX DUCT

a. Install the bolt and No. 2 console box duct.

11. INSTALL FLOOR CARPET BRACKET RH
12. INSTALL FLOOR CARPET BRACKET LH
13. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (w/o DVD Player)
14. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (w/ DVD Player)
15. INSTALL ROOM TEMPERATURE SENSOR
16. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY
17. INSTALL PUSH START SWITCH
18. INSTALL NO. 1 INSTRUMENT PANEL MOUNTING BRACKET
19. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY
20. INSTALL NO. 1 SPEAKER HOLE COVER
21. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY
22. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for LH Side)
23. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
24. INSTALL FRONT PILLAR GARNISH LH
25. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY
26. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for RH Side)
27. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY
28. INSTALL FRONT PILLAR GARNISH RH
29. INSTALL REAR CONSOLE BOX ASSEMBLY
30. INSTALL CONSOLE REAR END PANEL SUB-ASSEMBLY
31. INSTALL CONSOLE BOX CARPET
32. INSTALL CONSOLE BOX POCKET
33. INSTALL HEATER SEAT SWITCH CONSOLE BASE (w/o Seat Heater System)
34. INSTALL HEATER SEAT SWITCH CONSOLE BASE (w/ Seat Heater System)
35. INSTALL INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System)
36. INSTALL MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System)
37. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY
38. INSTALL UPPER CONSOLE PANEL ASSEMBLY WITH FRONT ASH RECEPTACLE
39. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
40. INSTALL LOWER INSTRUMENT PANEL RH
41. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY
42. INSTALL SIDE INSTRUMENT PANEL RH
43. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
44. INSTALL FRONT DOOR OPENING TRIM COVER RH
45. INSTALL FRONT DOOR SCUFF PLATE RH
46. INSTALL INSTRUMENT PANEL FINISH PANEL END RH
47. INSTALL NO. 1 SWITCH HOLE BASE
48. INSTALL COMBINATION METER ASSEMBLY
49. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
50. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE
51. INSTALL TILT & TELESCOPIC SWITCH
52. INSTALL STEERING COLUMN COVER
53. ADJUST SPIRAL CABLE SUB-ASSEMBLY
54. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY
55. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
56. INSTALL SIDE INSTRUMENT PANEL LH
57. INSTALL FRONT DOOR OPENING TRIM COVER LH
58. INSTALL FRONT DOOR SCUFF PLATE LH
59. INSTALL STEERING WHEEL ASSEMBLY
60. INSTALL STEERING PAD
61. INSTALL LOWER NO. 3 STEERING WHEEL COVER
62. INSTALL LOWER NO. 2 STEERING WHEEL COVER

63. INSTALL HEATER INLET WATER HOSE

a. Install the water hose and attach the clip.

64. INSTALL HEATER OUTLET WATER HOSE
a. Use the same procedure described for the heater inlet water hose.

65. INSTALL AIR CONDITIONER TUBE AND ACCESSORY
a. Remove the attached vinyl tape from the tube.
b. Sufficiently apply compressor oil to a new O-ring and fitting surface of the air conditioning tube assembly.

Compressor oil: ND-OIL 8 or equivalent

c. Install the O-ring on the air conditioner tube and accessory.
d. Install the air conditioner tube and accessory.

66. INSTALL SUCTION HOSE SUB-ASSEMBLY

a. Remove the attached vinyl tape from the hose.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

Compressor oil: ND-OIL 8 or equivalent

c. Install the O-ring on the suction hose sub-assembly.
d. Move the hook connector in the direction indicated by the arrow in the illustration.
e. Insert the pipe joint into the fitting hole securely and tighten the bolt.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)

67. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
68. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
69. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
70. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
71. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
72. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
73. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
74. INSPECT STEERING PAD
75. INSPECT FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY

76. INSPECT SRS WARNING LIGHT
a. Inspect the SRS warning light.

77. PERFORM INITIALIZATION

NOTE: Some systems need initialization after reconnecting the negative battery terminal.

78. ADD ENGINE COOLANT
79. CHECK FOR ENGINE COOLANT LEAKS
80. CHARGE WITH REFRIGERANT
81. WARM UP COMPRESSOR
82. CHECK FOR REFRIGERANT LEAKS
83. INSTALL ENGINE ROOM SIDE COVER RH
84. INSTALL ENGINE ROOM SIDE COVER LH
85. INSTALL HOOD HINGE COVER (for RH Side)
86. INSTALL HOOD HINGE COVER (for LH Side)
87. INSTALL COOL AIR INTAKE DUCT SEAL