With Air Conditioning

REMOVAL






If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor.

WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH ENGINE OFF. REFER TO REFRIGERANT WARNINGS IN HEATING AND AIR CONDITIONING.

1. Disconnect battery negative cable.
2. Partially drain cooling system. Refer to COOLING SYSTEM-DRAINING and FILLING.
Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
3. Remove upper radiator hose clamp and hose at radiator.
4. Unplug wiring harness from A/C compressor.
5. Remove air cleaner assembly.






6. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt.
7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley.
8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket.
9. Disconnect throttle body control cables. Refer to ACCELERATOR PEDAL and THROTTLE CABLE in Powertrain Management for procedure.
10. Remove heater hose clamp and heater hose from heater hose coolant return tube.






11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring.
12. Remove bracket-to-intake manifold bolts (number 1 and 2).
13. Remove six bracket bolts (number 3).
14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position.
15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle.

INSTALLATION
1. Position bypass hose clamps to center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2) to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3) to 40 Nm (30 ft. lbs.) torque.
5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine.
7. Connect throttle body control cables.
8. Install oil dipstick mounting bolt.
9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque.
10. Relax tension from belt tensioner. Install drive belt.






CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to figure for correct belt routing. The correct belt with correct length must be used.

11. Install air cleaner assembly.
12. Install upper radiator hose to radiator.
13. Connect wiring harness to A/C compressor.
14. Connect battery negative cable.
15. Fill cooling system. Refer to Draining and Filling Cooling System.
16. Start and warm the engine. Check for leaks.