Repair Procedure 2

31. Set the air mix control switch to MAX COOL.

HINT:
This operation makes it possible to verify proper installation.

A. Temporarily connect the cable from the negative (-) battery terminal.
B. Set the air mix control switch to MAX COOL.
C. Disconnect the cable from the negative (-) battery terminal.







32. Install the evaporator.

NOTE:
Check that the packing is installed to the new heater case.

A. Install the cooler thermostat and cooler evaporator on the case.
B. Attach the 2 claws to install the heater case.
C. Hold the heater doors with your finger as shown in the illustration when installing the heater case.







D. Install the 4 screws.

33. Check operation.
A. Connect the cable from the negative (-) battery terminal.
B. Check that the air mix control switch operates without any abnormal noise.
C. Disconnect the cable from the negative (-) battery terminal.







34. Connect the evaporator temperature sensor.
A. Attach the connector to the air conditioning unit.







B. Connect the connector.







35. Install the bracket from the heater case.

NOTE:
The bracket is reused.







36. Install the air conditioning amplifier.
A. Place the A/C amplifier toward the bracket on the heater case.
B. Install the screw for the A/C amplifier.
C. Attach the clamp.







37. Install the cooler expansion valve.
A. Install the 2 NEW O-rings to the cooler evaporator and install the cooler expansion valve.
B. Using a 4-mm hexagon wrench, install the 2 hexagon bolts.

Torque: 3.5 N-m (35 kgf-cm, 30 in.-lbf)







38. Install the tube sub-assembly.
A. Remove the attached vinyl tape from the pipe.
B. Apply compressor oil to the 2 NEW O-rings and the fitting surface of the suction tube and liquid tube. Compressor Oil: ND-OIL 8 or equivalent
C. Install the 2 NEW O-rings on the suction tube and liquid tube.
D. Connect the suction tube and liquid tube.

NOTE:
After the connection, check that the claw of the piping clamp is engaged.

E. Install the plate with the bolt.
Torque: 9.8 N-m ( 100 kgf-cm, 7 ft-lbf )







39. Install the blower assembly.

A. Install the blower assembly.
B. Connect the connector of the air inlet control servo motor.







C. Install the three screws.







D. Install the 4 bolts and 1 nut.







E. Install the clip for wire harness.
F. Connect the wire harness connector to the blower assembly.







40. Install the dash panel insulator pad No. 2.

A. Install the dash panel insulator pad No. 2.
B. Install the floor carpet at passenger side.







41. Attach the rear air duct and attach the 3 claws.







42. Install the rear console box subassembly.
A. Connect the connector and install the rear console box.
B. Install the 2 bolts and 2 screws.
C. Install the console box carpet.







43. Install the No. 1 instrument panel bracket cover inner RH and attach the 2 claws.







44. Install the No. 1 instrument panel bracket cover inner LH and attach the 2 claws.







45. Install the console rear end panel (RSE type) by attaching the 2 clips and 4 claws







46. Install the console rear end panel by attaching the 6 claws.







47. Install the upper rear console panel sub-assembly.

A. Connect the connector.
B. Attach the 4 clips to install the upper rear console panel.







48. Install the console cup holder box.
A. Attach the 2 clips to install the cup holder box.
B. Install the 2 screws.







49. Install the switch base.
A. Connect the connectors.
B. Attach the 2 clips and 2 claws to install the switch base.







50. Install the upper console panel subassembly.
A. Connect the connector.
B. Attach the 2 clips and 4 claws to install the upper console panel.
C. Install the shift lever knob.







51. Install the No. 2 console upper panel garnish by attaching the 4 clips.







52. Install the No. 1 console upper panel garnish by attaching the 4 clips.







53. Install the cowl side trim board.
A. Install the trim board and attach the 2 claws.
B. Install the cap nut.







54. Install the front door scuff plate RH by attaching the 10 claws.







55. Install the glove compartment door assembly.
A. Attach the 2 hinges to install the door.







B. Attach the claw to the glove compartment door stopper.
C. While pushing in the sides of the glove compartment door as indicated by the arrows in the illustration, close the door to engage it to the 2 stoppers.







56. Install the No. 2 instrument panel under cover sub-assembly by attaching the 2 claws.

57. Connect the cable to the negative (-) battery cable.

58. Charge refrigerant to refrigerant system.

A. Use a vacuum pump to evacuate the system.
B. Charge refrigerant HFC-134a (R134a).
Standard: 450 +/-30 g (15.9 +/- 1.1 oz)







NOTE:
- Do NOT operate the A/C compressor before charging refrigerant as the A/C compressor will NOT work properly without any refrigerant and will overheat.
- Approximately 100 g (3.53 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and NOT with the sight glass.

59. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant.

NOTE:
To prevent damage to the A/C compressor, warm the engine up before turning the A/C ON.







60. Inspect for refrigerant leaks.
61. Inspect the operation of the "Mode" and temperature controls.
A. Verify that the air conditioner temperature is the same from all the dash vents.
B. Verify that the heater temperature is the same from all the dash vents.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.