Removal and Installation
REMOVAL1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1
a. Install SST on piping clamp.
SST 09870-00015
HINT: Make sure the direction of the piping clamp claw and SST by seeing the illustration shown on the caution label.
b. Push down the SST and release the clamp lock.
NOTE: Be careful not to deform the tube when pushing SST.
c. Pull SST slightly and push the release lever, and then remove the piping clamp with SST.
d. Disconnect the cooler refrigerant suction hose No.1.
NOTE:
- Do not use tools like screwdriver to remove the tube.
- Cap the open fittings immediately to keep moisture of dirt out of the system.
e. Remove the 2 O-rings from the cooler refrigerant suction hose No.1.
3. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
SST 09870-00025
HINT: Disconnect of the air conditioning tube and accessory assembly is same as the cooler refrigerant suction hose No.1.
4. DISCONNECT HEATER WATER OUTLET HOSE
a. Using pliers, grip the claws of the clip and slide the clip, and then disconnect the heater water outlet hose.
NOTE:
- Do not apply any excessive force to the heater water outlet hose.
- Prepare a drain pan or cloth for when the cooling water leaks.
5. DISCONNECT HEATER WATER INLET HOSE
a. Disconnection of the heater water inlet hose is same as the heater water outlet hose.
6. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
HINT: Refer to the instructions for removal of the instrument panel passenger airbag assembly.
7. DISCONNECT STEERING COLUMN ASSEMBLY
a. Remove the 2 bolts and 2 nuts, disconnect the steering column assembly form the instrument panel reinforcement assembly.
8. DISCONNECT FLOOR SHIFT ASSEMBLY
a. Remove the 2 nuts and disconnect the shift cable.
b. Remove the 4 nuts and disconnect floor shift assembly.
9. REMOVE AIR DUCT REAR NO.2
a. Remove the side scuff plate.
b. Take up the floor carpet.
HINT: Take up the floor carpet so that the air duct rear No.2 can be removed.
c. Remove the air duct rear No.2.
10. REMOVE AIR DUCT REAR NO.1
HINT: Remove it in the same way with the air duct rear No.2.
11. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.1
a. Disconnect the harness clamp.
b. Remove the 3 bolts, 2 nuts and instrument panel brace sub-assembly No.1.
12. REMOVE INSTRUMENT PANEL BRACE SUB-ASSEMBLY NO.2
a. Disconnect the harness clamp.
b. Remove the 2 bolts, 2 nuts and instrument panel brace sub-assembly No.2.
13. REMOVE AIR CONDITIONER AMPLIFIER ASSEMBLY (w/ Navigation System)
14. REMOVE ECM
a. Disconnect the connector.
b. Remove the 2 nuts, and ECU.
15. REMOVE MULTIPLEX NETWORK BODY ECU
a. Disconnect the connector.
b. Remove the 2 nuts and multiplex network body ECU.
16. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY
a. Remove the bolt and 2 nuts, disconnect the instrument panel junction block assembly.
17. REMOVE SKID CONTROL ECU ASSEMBLY
a. Disconnect the connector.
b. Remove the 2 nuts and skid control ECU assembly.
18. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Remove the 5 bolts, 4 nuts and instrument panel reinforcement assembly.
19. REMOVE AIR CONDITIONER UNIT ASSEMBLY
a. Disconnect the connector and clamp.
b. Disconnect the connector connecting the wiring air indicator harness sub-assembly and vehicle harness.
c. Remove the 2 bolts, 2 nuts and air conditioner unit assembly.
20. REMOVE AIR CONDITIONING RADIATOR ASSEMBLY
a. Remove the screw, disconnect the connected part of the duct and take off the air duct No.2.
b. Remove the 4 screws and bracket.
c. Disconnect the connection between the blower assembly and the air conditioning radiator assembly and remove the air conditioning radiator assembly.
INSTALLATION
1. INSTALL AIR CONDITIONING RADIATOR ASSEMBLY
2. INSTALL AIR CONDITIONER UNIT ASSEMBLY
a. Install the air conditioner unit assembly with the 2 bolts and 2 nuts.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
b. Connect the connectors connecting the wiring air indicator No.2 harness and vehicle harness.
c. install the connector and clamp.
3. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY
a. Install the instrument panel reinforcement assembly with the 5 bolts and 4 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
4. INSTALL SKID CONTROL ECU ASSEMBLY
a. Install the skid control ECU assembly with the 2 nuts.
Torque: 5.0 N.m (50 kgf.cm, 43 in.lbf)
5. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY
a. Install the instrument panel junction block assembly with the bolt and 2 nuts.
Torque: 8.4 N.m (86 kgf.cm, 74 in.lbf)
6. INSTALL ECM
a. Install the ECM with the 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
7. INSTALL MULTIPLEX NETWORK BODY ECU
a. Install the multiplex network body ECU with the bolt and 2 nuts.
8. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY (With Navigation)
9. INSTALL INSTRUMENT PANEL BRACE NO.2 SUB-ASSEMBLY
a. Install the instrument panel brace No.2 subassembly with the 2 bolts and 2 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
10. INSTALL INSTRUMENT PANEL BRACE NO.1 SUB-ASSEMBLY
a. Install the instrument panel brace No.1 subassembly with the 3 bolts and 2 nuts.
Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)
11. INSTALL AIR DUCT REAR NO.2
a. Install the air duct rear No.2.
b. Install the side scuff plate.
12. INSTALL AIR DUCT REAR NO.1
13. INSTALL FLOOR SHIFT ASSEMBLY
a. Install the floor shift assembly with the 4 nuts.
Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
NOTE: Tighten the nuts in numerical order shown in the illustration to install the floor shift assembly.
b. Install the shift cable with the 2 nuts.
Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)
14. INSTALL STEERING COLUMN ASSEMBLY
a. Install the steering column assembly with the 2 bolts and 2 nuts.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
15. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
HINT:Refer to the installation procedures for the instrument panel passenger airbag.
16. INSTALL HEATER WATER INLET HOSE
17. INSTALL HEATER WATER OUTLET HOSE
18. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
a. Remove the attached vinyl tape from the tube.
b. Coat a new O-ring with compressor oil and install them to the hose.
Compressor oil:
ND-OIL 8 or equivalent
c. Install the air conditioning tube and accessory and piping clamp.
HINT:
- Be sure to connect the pipe securely.
- After connection, check the fitting for claw of the piping clamp.
19. INSTALL COOLER REFRIGERANT SUCTION NO.1 HOSE
a. Remove the attached vinyl tape from the hose.
b. Coat a new O-ring with compressor oil and install it to the pipe.
Compressor oil:
ND-OIL 8 or equivalent
c. Install the cooler refrigerant suction No.1 hose and piping clamp.
20. ADD COOLANT
21. CHARGE REFRIGERANT
22. CHECK FOR ENGINE COOLANT LEAKS
23. WARM UP COMPRESSOR
24. CHECK FOR LEAKAGE REFRIGERANT