Page 3017 of 3189

Lubricant Adjusting Procedure for Components
Replacement Except Compressor
=NJHA0160S0201After replacing any of the following major components, add the
correct amount of lubricant to the system.
Amount of lubricant to be added
Part replacedLubricant to be added to
system
Remarks
Amount of lubricant
m(Imp fl oz)
Evaporator 75 (2.6) —
Condenser 35 (1.2) —
Liquid tank 5 (0.2)Add if compressor is not
replaced. *1
In case of refrigerant
leak30 (1.1) Large leak
— Small leak *2
*1: If compressor is replaced, addition of lubricant is included in the table.
*2: If refrigerant leak is small, no addition of lubricant is needed.
Lubricant Adjustment Procedure for Compressor
Replacement
NJHA0160S02021. Discharge refrigerant into the refrigerant recovery/recycling
equipment. Measure lubricant discharged into the recovery/
recycling equipment.
2. Drain the lubricant from the “old” (removed) compressor into a
graduated container and recover the amount of lubricant
drained.
3. Drain the lubricant from the “new” compressor into a separate,
clean container.
4. Measure an amount of new lubricant installed equal to amount
drained from “old” compressor. Add this lubricant to “new” com-
pressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount
recovered during discharging. Add this lubricant to “new” com-
pressor through the suction port opening.
6. If the liquid tank also needs to be replaced, add an additional
5m(0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m(0.2 Imp fl oz) of lubricant if only
replacing the compressor.
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SERVICE PROCEDUREMANUAL
Maintenance of Lubricant Quantity in Compressor (Cont’d)
HA-81
Page 3018 of 3189
RHA065DH
Compressor
REMOVAL AND INSTALLATIONNJHA0161
RJIA0833E
SERVICE PROCEDUREMANUAL
Maintenance of Lubricant Quantity in Compressor (Cont’d)
HA-82
Page 3019 of 3189
RJIA0834E
Compressor Clutch — CSV613 (CALSONIC
make)
OVERHAULNJHA0211
RHA805H
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SERVICE PROCEDUREMANUAL
Compressor (Cont’d)
HA-83
Page 3020 of 3189
RHA136E
REMOVALNJHA0212When removing center bolt, hold clutch disc with clutch disc
wrench.
RHA399FA
RHA124FA
Remove the clutch disc using the clutch disc puller.
Insert the holder’s three pins into the holes in the clutch disc.
Rotate the holder clockwise to hook it onto the plate. Then,
tighten the center bolt to remove the clutch disc.
After removing the clutch disc, remove the shims from either
the drive shaft or the clutch disc.
RHA138E
Remove the snap ring using external snap ring pliers.
RHA139E
Pulley removal
Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail-
able pulley puller.
To prevent the pulley groove from being deformed, the
puller claws should be positioned onto the edge of the
pulley assembly.
SERVICE PROCEDUREMANUAL
Compressor Clutch — CSV613 (CALSONIC make) (Cont’d)
HA-84
Page 3021 of 3189
RHA806H
Remove the connector from the connector bracket.
RHA145E
Remove the snap ring using external snap ring pliers.
RHA126F
INSPECTIONNJHA0213Clutch DiscNJHA0213S01If the contact surface shows signs of damage due to excessive
heat, replace clutch disc and pulley.
PulleyNJHA0213S02Check the appearance of the pulley assembly. If the contact sur-
face of pulley shows signs of excessive grooving, replace clutch
disc and pulley. The contact surfaces of the pulley assembly should
be cleaned with a suitable solvent before reinstallation.
CoilNJHA0213S03Check coil for loose connection or cracked insulation.
RHA142E
INSTALLATIONNJHA0214Install the field coil.
Be sure to align the coil’s pin with the hole in the com-
pressor’s front head.
Install the field coil harness clip using a screwdriver.
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SERVICE PROCEDUREMANUAL
Compressor Clutch — CSV613 (CALSONIC make) (Cont’d)
HA-85
Page 3022 of 3189
RHA143E
Install the pulley assembly using the installer and a hand
press, and then install the snap ring using snap ring pliers.
RHA127F
Install the clutch disc on the drive shaft, together with the
original shim(s). Press the clutch disc down by hand.
RHA086E
Using the holder to prevent clutch disc rotation, tighten the bolt
to 14 N·m (1.4 kg-m, 10 ft-lb) torque.
After tightening the bolt, check that the pulley rotates
smoothly.
RHA087E
Check clearance around the entire periphery of clutch disc.
Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
Break-in OperationNJHA0214S01When replacing compressor clutch assembly, always carry out the
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of
transmitted torque.
SERVICE PROCEDUREMANUAL
Compressor Clutch — CSV613 (CALSONIC make) (Cont’d)
HA-86
Page 3023 of 3189

Heater & Cooling Unit (Heater Core)
REMOVALNJHA0193
RHA807H
1. Drain the cooling system. Refer to LC-17 (QG), LC-43 (YD),
“Changing Engine Coolant”.
2. Discharge the A/C system. Refer to HA-77.
3. Disconnect the two heater hoses from inside the engine com-
partment.
4. Remove the blower unit. Refer to HA-89.
5. Remove the steering member assembly. Refer to BT-25, “Instru-
ment Panel Assembly”.
6. Remove the heater unit.
7. Separate the heater & cooling unit case, and remove the
heater core.
INSTALLATIONNJHA0194Install in the reverse order of removal.
When filling radiator with coolant, refer to LC-18 (QG), LC-43
(YD), “Refilling Engine Coolant”.
Recharge the A/C system. Refer to HA-77.
RJIA0185E
A/C Evaporator
REMOVALNJHA02041. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Disconnect the low-pressure flexible hose and the high-pres-
sure pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and the
high-pressure pipe with a suitable tool such as a vinyl tape to
avoid the entry of air.
3. Hold expansion valve and move it slightly upward. Push
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SERVICE PROCEDUREMANUAL
Heater & Cooling Unit (Heater Core)
HA-87
Page 3024 of 3189
evaporator toward rear of vehicle.
4. Remove the drain hose and lower cover mounting screw.
RHA674H
5. Slide evaporator toward vehicle rear.
RJIA0189E
6. Swivel rear of lower case toward passenger seat to remove
lower case.
7. Remove the intake sensor from evaporator.
8. Slide the evaporator to backward, then remove it from the
heater & cooling unit.
RJIA0840E
INSTALLATIONNJHA02051. Set the expansion valve to cooler grommet.
RJIA0841E
2. Install the evaporator to heater & cooling unit.
SERVICE PROCEDUREMANUAL
A/C Evaporator (Cont’d)
HA-88