Air Conditioning Unit

Air Conditioning Unit:

AIR CONDITIONING UNIT

REMOVAL

HINT:
- Installation is in the reverse order of removal.
- COMPONENTS for instrument panel safety pad sub-assembly.

1. DISCONNECT BATTERY NEGATIVE TERMINAL
a. Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

2. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH
3. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
4. REMOVE COWL TOP VENTILATOR LOUVER RH
5. REMOVE WINDSHIELD WIPER MOTOR AND LINK

6. REMOVE COWL TOP OUTSIDE PANEL FRONT
a. Remove the 4 bolts, 2 nuts and cowl top outside panel front.

7. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
a. Remove the bolt, and slide the hook connector.
b. Disconnect the suction hose 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 moisture and foreign matter from entering.

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

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

10. DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT)
a. Slide the clip and disconnect the heater water outlet hose A.

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

11. DISCONNECT HEATER WATER INLET HOSE A
a. Slide the clip and disconnect the heater water inlet hose A.

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

12. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

HINT: Refer to the removal procedures for the instrument panel safety pad sub-assembly w/ front passenger airbag assembly.

13. REMOVE HEATER TO REGISTER DUCT NO.2
a. Remove the 3 clips and heater to register duct No.2.

14. REMOVE HEATER TO REGISTER DUCT ASSEMBLY NO.6
a. Disengage the 4 claws and then remove the heater to register duct No.6.

15. REMOVE CONSOLE BOX DUCT NO.1
a. Remove the clip and console box duct No.1.

16. REMOVE FLOOR CARPET BRACKET LH

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

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

17. REMOVE FLOOR CARPET BRACKET RH

a. Release the 3 clamps.
b. Turn back the floor carpet.

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

18. REMOVE AIR DUCT REAR NO.2
a. Release the 2 claws and remove the air duct rear No.2.

19. REMOVE AIR DUCT REAR NO.1
a. Release the 2 claws and remove the air duct rear No.1.

20. REMOVE AIR DUCT SUB-ASSEMBLY NO.1
21. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
22. REMOVE STEERING COLUMN ASSEMBLY

23. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

a. Disconnect each connector and remove each clamp. Disconnect the wire harness.
b. Remove the 6 nuts and 3 bolts.
c. Remove the 3 bolts and nut.
d. Using a "Torx" socket wrench (T40), remove the 5 "Torx" bolts.

HINT: The "Torx" bolts on the passenger side can be removed with the collar or for adjustment.

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

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

NOTE: Tighten the bolts and screws in the order shown 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 hexagon wrench 12 mm, install the instrument panel reinforcement assembly with the 2 bolts.

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 in.lbf)

d. Install the 3 bolts and nut.

Torque: NUT 9.8 N.m (100 kgf.cm, 87 in.lbf)
BOLT A 20 N.m (204 kgf.cm, 15 ft.lbf)

e. Connect the connectors and clamps.

f. Install the 6 nuts and 3 bolts.

2. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY
3. INSTALL STEERING COLUMN ASSEMBLY
4. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
5. 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 liquid tube sub-assembly.
d. Install the liquid tube sub-assembly.

6. INSTALL SUCTION HOSE SUB-ASSEMBLY
a. Remove the attached vinyl tape from 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)

7. CONNECT BATTERY NEGATIVE TERMINAL
8. PERFORM SYSTEM INITIALIZE
a. Some system need initialization when disconnecting the cable from the negative battery terminal.

9. ADD ENGINE COOLANT
10. CHECK FOR ENGINE COOLANT LEAKS
11. CHARGE REFRIGERANT
12. WARM UP ENGINE
13. INSPECT FOR REFRIGERANT LEAK
14. INSTALL WINDSHIELD WIPER MOTOR AND LINK
15. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH
16. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH