
REFRIGERANT LINES
MTC-81
< SERVICE INFORMATION >
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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
SJIA0679E
SJIA0680E
SJIA0681E 

MTC-82
< SERVICE INFORMATION >
REFRIGERANT LINES
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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REFRIGERANT LINES
MTC-85
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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.
AHA281A 

MTC-86
< SERVICE INFORMATION >
REFRIGERANT LINES
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
SHA707EA
SHA706E
SHA708EA 

HARNESS
PG-39
< SERVICE INFORMATION >
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C2 M6 W/4 : Steering lock solenoid E2 M52 W/40 : Intelligent key unit
B3 M7 W/16 : Door mirror remote control switch B2 M53 W/16 : EPS control unit
A3 M8 W/16 : To D2 B3 M54 B/2 : EPS control unit
A3 M9 W/16 : To D1 C3 M55† W/4: Hazard switch (hatchback early 
  production)
E2 M10 GR/2 : Instrument panel antenna  D2 M55†† W/4: Hazard switch (hatchback late production
  or sedan)
G3 M11 W/4 : To B106 B2 M57 — : Body ground
G4 M12 W/16 : To B101 F2 M59 W/2 : Glove box lamp
G3 M13 W/24 : To B102 C1 M60 L/2 : EPS control unit
G3 M14 W/24 : To B120 F1 M61 — : Body ground
B4 M15 W/16 : To B23 E2 M62 W/2 : Front blower motor 
B4 M16 W/24 : To B24 C1 M63 W/4 : Torque sensor
D5 M17 B/1 : Parking brake switch A2 M69 SMJ : To E7
F2 M18 W/40 : BCM (body control module) B2 M73 GR/6: Key switch and ignition knob switch (With   
intelligent key)
F2 M19 W/15 : BCM (body control module) G3 M74 W/12 : To D102
F3 M20 B/15 : BCM (body control module) G3 M75 W/12 : To D101
C2 M21 W/4 : NATS antenna amp.  F2 M77 Y/4 : Front passenger air bag module
B3 M22 W/16 : Data link connector A2 M78 B/2 : To E11
E3 M23 W/4 : Remote keyless entry receiver B1 M79 — : Body ground
C1 M24 W/40 : Combination meter D3 M150 W/4 : To M32
C3 M25 /2 : Diode-1 C3 M151 W/4 : Front blower motor resistor
B2 M26 W/6 : Ignition switch
C2 M27 GR/6 : Key switch and key lock solenoid
C2 M28 W/16 : Combination switch 
C3 M29 Y/6 : Combination switch (spiral cable)
C3 M30 GR/8 : Combination switch (spiral cable)
E3 M32 W/4 : To M150
D2 M33 B/15 : Front air control
D4 M35 Y/28 : Air bag diagnosis sensor unit
D2 M36† W/3: Front passenger air bag OFF indicator
  (hatchback early production)
C3 M36†† W/3: Front passenger air bag OFF indicator
  (hatchback late production or sedan)
D4 M38 W/6 : A/T device
D4 M38 W/6 : CVT device (without intelligent key)
D4 M38 W/8 : CVT device (with intelligent key)
B3 M39 W/2 : Tire pressure warning check connector
D2 M41 W/2 : Defrost A/C switch 
D3 M42 W/3 : Thermo control amp. (without CVT)
D2 M43 W/20 : Audio unit 

PG-40
< SERVICE INFORMATION >
HARNESS
ENGINE ROOM HARNESS (LH VIEW)
Refer to "ENGINE ROOM HARNESS (RH VIEW)"  for continuation of engine room harness.
LKIA0815E
C4 E3 GR/4 : Cooling fan motor (without A/C) C3 E47 BR/8: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room)
C4 E3 B/2 : Cooling fan motor (with A/C) D3 E48 B/6: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room)
C4 E5 GR/3 : Resistor D1 E51 B/2 : Front wheel sensor LH 

HARNESS
PG-41
< SERVICE INFORMATION >
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C3 E6 — : Fuse and fusible link box D3 E53 B/2: Front combination lamp LH
  (parking)
B1 E7 SMJ : To M69
D3 E8 SMJ : To F8
B4 E9 BR/2 : Fusible link box (battery)
B3 E10 GR/2 : Fusible link box (battery)
B1 E11 B/2 : To M78
A3 E12 B/6 : Accelerator pedal position sensor
A2 E13 B/2 : Stop lamp switch (with M/T)
A2 E13 W/4 : Stop lamp switch (without M/T)
D3 E14 — : Engine ground (crash zone sensor)
C2 E15 — : Engine ground
B2 E16 B/32 : ECM
C5 E18 B/1 : Horn (low) 
C4 E19 GR/6 : To F33
D5 E20 B/1 : Horn (low) 
D3 E25 B/3: Front combination lamp LH
  (headlamp)
E4 E27 B/2 : Front fog lamp LH
D4 E29 B/2: Front combination lamp LH
  (turn signal)
B1 E31 W/24 : TCM
B1 E32 GR/24 : TCM
A2 E34 BR/2 : Clutch interlock switch (with M/T)
A2 E35 BR/2 : ASCD clutch switch
A2 E36 BR/2 : ASCD brake switch
B4 E40 GR/2 : Brake fluid level switch 
D3 E42 B/2: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room)
C3 E43 W/16: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room)
C3 E44 W/6: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room)
D3 E45 BR/12: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room)
D3 E46 W/12: IPDM E/R (Intelligent Power Distribu-
  tion Module Engine Room) 

PG-42
< SERVICE INFORMATION >
HARNESS
ENGINE ROOM HARNESS (RH VIEW)
Refer to "ENGINE ROOM HARNESS (LH VIEW)"  for continuation of engine room harness.
LKIA0816E
G2 E1 GR/5 : Front wiper motor D3 E30 B/2: Front combination lamp RH
  (turn signal)
C3 E2 B/2 : Front and rear washer motor F2 E33 B/26: ABS actuator and electric unit (control
  unit)
F5 E4 Y/2 : Crash zone sensor E2 E37 B/5 : Daytime light relay 1