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INSPECTION FOR CLUTCH DISC TO PULLEY CLEARANCE
1. Check the clearance around the entire periphery of the clutch disc.
• Measure the clearance for the type 1 compressor as shown.
• Measure the clearance for the type 2 compressor as shown.
2. If specified clearance is not obtained, replace compressor.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones, and
apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of Low-Pressure Flexible HoseINFOID:0000000001704325
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove engine cover. Refer to EM-18
.
3. Remove cowl top cover. Refer to EI-21
.
4. Remove lower dash insulator.
5. Remove ground wire harness (1).
6. Remove bolt (A) and nut (B) from low-pressure flexible hose (2)
bracket.Clutch disc to pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in)
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Compressor bolts : 25 N·m (2.6 kg-m, 18 ft-lb)
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MTC-80
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7. Remove bolt (A), and then disconnect low-pressure flexible
hose (1) and high-pressure pipe (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
8. Remove nut (A), and then remove low-pressure flexible hose (1)
from compressor (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure Flexible HoseINFOID:0000000001704326
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove high-pressure flexible hose (1) bolt (A) from condenser
(2).
3. Remove bolt (A), and then remove high-pressure flexible hose
(1) from compressor (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
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Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings of high-pressure flexible hose with a new ones, and apply compressor oil when
installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure PipeINFOID:0000000001704327
REMOVAL
1. Remove low-pressure flexible hose. Refer to MTC-79, "Removal and Installation of Low-Pressure Flexible
Hose".
2. Remove high-pressure pipe from the clips.
3. Remove high-pressure pipe bolt (A), and then remove high-
pressure pipe (1) from condenser (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings of high-pressure pipe with a new ones, and apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of Refrigerant Pressure SensorINFOID:0000000001704328
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Disconnect connector, and then remove refrigerant pressure
sensor (1) from condenser (2).
CAUTION:
When working, be careful not to damage the condenser
fins.
1. High-pressure pipe A. High-pressure pipe clips
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MTC-82
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INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings of refrigerant pressure sensor with a new one, and apply compressor oil when
installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of CondenserINFOID:0000000001704329
REMOVAL
1. Remove the three upper headlamp bolts to reposition the headlamps out of the way
2. Remove the radiator core support upper. Refer to BL-19
.
3. Remove high-pressure flexible hose and high-pressure pipe from condenser. Refer to MTC-80, "
Removal
and Installation of High-pressure Flexible Hose" and MTC-81, "Removal and Installation of High-pres-
sure Pipe" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
4. Disconnect refrigerant pressure sensor connector.
5. Tilt radiator toward rear of vehicle, and then remove condenser
(1) from between radiator and radiator core support upper.
CAUTION:
Be careful not to damage the core surface of condenser and
radiator.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of Liquid TankINFOID:0000000001704330
REMOVAL
1. Remove the condenser. Refer to MTC-82, "Removal and Installation of Condenser" .
2. Clean liquid tank and its surrounding area, and remove dirt and rust from liquid tank.
CAUTION:
Be sure to clean carefully.
3. Remove bolts (A) and (B) from liquid tank.
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4. Remove liquid tank bracket (1) from protruding part of con-
denser (2).
5. Slide liquid tank (3) upward, and then remove liquid tank (3).
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Make sure liquid tank bracket (2) is securely installed at pro-
trusion of condenser (3). [Make sure liquid tank bracket (2)
does not move to a position below center of liquid tank (1).]
• Replace O-rings for A/C piping with new ones, and apply com-
pressor oil when installing.
• When recharging refrigerant, check for leaks. Refer to MTC-
84, "Checking of Refrigerant Leaks" .
Removal and Installation of EvaporatorINFOID:0000000001704331
REMOVAL
1. Remove A/C unit assembly. Refer to MTC-58 .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
2. Remove air conditioner filter. Refer to MTC-68
.
3. Remove foot duct (right). Refer to MTC-69, "
Removal and Installation" .
4. Remove screws (A), and then remove expansion valve cover
(1).
5. Remove screws (A), and then remove evaporator cover (1).
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6. Remove evaporator (1) with lower blower case (2) from A/C unit
assembly.
7. Remove thermo control amp. (3) from evaporator (1), if
equipped (TYPE 1 systems).
8. Remove evaporator (1) from lower blower case (2).
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
• Mark the position of the thermo control amp., if equipped (TYPE 1 systems).
• When recharging refrigerant, check for leaks.
Removal and Installation of Expansion ValveINFOID:0000000001704332
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove cowl top cover. Refer to EI-21
.
3. Remove lower dash insulator.
4. Disconnect low-pressure flexible hose and high-pressure pipe from evaporator. Refer to MTC-58
.
5. Remove expansion valve bolts (A), and then remove expansion
valve (1).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings of evaporator with new ones, and apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
Checking of Refrigerant LeaksINFOID:0000000001704333
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C oil leak-
age, damage and corrosion. A/C oil leakage may indicate an area of refrigerant leakage. Allow extra inspec-
tion time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak
detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 25 to 50 mm (1 to 2 in) per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
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Checking System for Leaks Using the Fluorescent Leak DetectorINFOID:0000000001704334
1. Check A/C system for leaks using the UV lamp and safety goggles J-42220 in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner J-43872 to prevent future misdiag-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and oils, may falsely trigger the leak detector. Make sure the surfaces to be checked are
clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionINFOID:0000000001704335
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2, 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool J-41459.
3. Connect the injector tool to the A/C low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak DetectorINFOID:0000000001704336
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
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1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
3. Move probe along component approximately 25 to 50 mm (1 to
2 in) per second.
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2, 50 psi) above 16°C. If less
than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2, 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet f) to the
low-pressure side (evaporator drain hose g to shaft seal k). Refer to MTC-76, "
Component". Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
• Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
• Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor.
• Liquid tank
Check the refrigerant connection.
• Service valves
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