Receiver/Dryer Desiccant Replacement
Note. Install the receiver/dryer as quickly as possible to prevent the system from absorbing moisture from the air.
Scheme 56
- Remove the A/C condenser (see «A/C CONDENSER REPLACEMENT»(ref-510445-S24192570992012102300000) ).
- Remove the cap (A) from the bottom of the A/C condenser. Remove the O-ring (B) and the desiccant (C).
- Install the receiver/dryer in the reverse order of removal, and note these items: Replace the O-rings with new ones, and apply a thin coat of refrigerant oil (DENSO ND-OIL 8) before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Install the cap to the specified torque. It is made of resin and can be easily stripped.
A/C Compressor Replacement
Note. Do not install the A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure.
Scheme 57
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- If the A/C compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
- Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-510445-S37673303752012102300000) ).
- Remove the drive belt (see «DRIVE BELT REPLACEMENT»(ref-510446-S42712127132012102300000) ).
- Remove the front splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-510458-S02765418422012102300000) ).
- Remove the front undercover (see «FRONT UNDERCOVER REPLACEMENT»(ref-510458-S39595599002012102300000) ).
- Support the front subframe with the engine support. Remove the bolts and the front subframe stiffener (A). NOTE: Install the new front subframe mounting bolt (B).
- Disconnect the A/C compressor clutch connector (A). Remove the bolts and the nut, then disconnect the suction hose (B) and discharge hose (C) from the A/C compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
- Remove the mounting bolts and the A/C compressor (A). Be careful not to damage the radiator fins when removing the A/C compressor.
- Install the A/C compressor in the reverse order of removal, and note these items: Before installing a new A/C compressor, adjust the A/C compressor oil level (see «A/C REFRIGERANT OIL REPLACEMENT»(ref-510445-S07643016422012102300000) ). Inspect the A/C lines for any signs of contamination. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Use refrigerant oil (DENSO ND-OIL 8) for HFC-134a DENSO piston type A/C compressor only. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Be careful not to damage the radiator fins when installing the A/C compressor and the A/C condenser fan shroud. Charge the system (see «SYSTEM CHARGING»(ref-510445-S24289370452012102300000) ).
A/C Refrigerant Oil Replacement
Recommended PAG oil: DENSO ND-OIL 8
- P/N 38897-PR7-A01AH: 120 mL (4fl.oz) Add the recommended refrigerant oil in the amount listed if you replace any of the following parts.
- To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
- Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
- Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately.
A/C condenser (including dryer desiccant)......... 50 mL(1 2/3 fl.oz)
Front Evaporator...... 40 mL(1 1/3 fl.oz)
Rear Evaporator........ 30 mL (1 fl.oz)
Line or hose.............. 10 mL (1/3 fl.oz)
Dryer desiccant......... 10 mL (1/3 fl.oz)
Leakage repair.......... 25 mL (5/6 fl.oz)
A/C compressor........ For A/C compressor replacement, subtract the volume of oil drained from the removed A/C compressor from 125 mL (4 2/9 fl.oz), and drain the calculated volume of oil from the new A/C compressor: 125 mL (4 2/9 fl.oz) - Volume of removed A/C compressor = Volume to drain from new A/C compressor.
Note. Even if no oil is drained from the removed A/C compressor, don't drain more than 50 mL (1 2/3 fl.oz) from the new A/C compressor.
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- Open the glove box. Remove the glove box stop on right side, then let the glove box hang down (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-510494-S12847216142012102300000) ).
- Remove the dust and pollen filter assembly (A) from the blower unit.
- Remove the filter (A) from the housing (B), and replace the filter.
- Install the filter in the reverse order of removal. Make sure that there is no air leaking out of the blower unit.
Scheme 64
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- Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-510494-S12847216142012102300000) ).
- Detach the harness clips (A), then remove the bolts, and the glove box frame (B).
- Cut the plastic cross brace (A) in the glove box opening with diagonal cutters in the area shown, and discard it.
- Detach the wire harness clip (A), then remove the self-tapping screws, and the passenger's heater duct (B).
- Disconnect the connector (A) from the front blower motor, then detach the wire harness clips (B).
- Disconnect the connectors (A) from the recirculation control motor and headlight leveling control unit, then detach the harness clip (B). Remove the self-tapping screws, the mounting nuts, and the blower unit (C).
- Install the unit in the reverse order of removal. Make sure that there is no air leakage.
Blower Unit Component Replacement
Note these items when overhauling the blower unit
Scheme 69
- The recirculation control motor (A), the front blower motor (B) and the dust and pollen filter (C) can be replaced without removing the blower unit.
- Before reassembly, make sure that the recirculation control linkage and door move smoothly without binding.
- After reassembly, make sure the recirculation control motor runs smoothly (see «RECIRCULATION CONTROL MOTOR TEST»(ref-510445-S30507258362012102300000) ).
Scheme 70
- Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-510445-S37673303752012102300000) ).
- Remove the front evaporator core (see «FRONT EVAPORATOR CORE REPLACEMENT»(ref-510445-S41210150842012102300000) ).
- Remove the bolts, then remove the front expansion valve (A) and O-rings (B).
- Install the front expansion valve in the reverse order of removal, and note these items: Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Make sure that there are no leaks. Charge the system (see «SYSTEM CHARGING»(ref-510445-S24289370452012102300000) ).
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- Recover the refrigerant with a recovery/recycling/charging station (see «REFRIGERANT RECOVERY»(ref-510445-S37673303752012102300000) ).
- Remove the bolts.
- Remove the bolts, then disconnect the front receiver line (A) and the front suction line (B) from the front evaporator core. Replace the O-rings (C).
- Remove the blower unit (see «BLOWER UNIT REMOVAL/INSTALLATION»(ref-510445-S12465463532012102300000) ).
- Disconnect the connector (A) from the front power transistor, then detach the harness clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal (D).
- Remove the bolts, the inlet and outlet pipes (A), and expansion valve (B). Carefully pull out the front evaporator core (C), then remove the plate (D). Replace the O-rings (E).
- Install the core in the reverse order of removal, and note these items: If you're installing a new front evaporator core, add refrigerant oil (DENSO ND-OIL 8) (see «A/C REFRIGERANT OIL REPLACEMENT»(ref-510445-S07643016422012102300000) ). Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Make sure that there is no air leakage. Charge the system (see «SYSTEM CHARGING»(ref-510445-S24289370452012102300000) ).
Heater Unit/Core Replacement
SRS components are located in this area. Review the SRS component locations (see COMPONENT LOCATION INDEX ), and the precautions and procedures (see PRECAUTIONS AND PROCEDURES ) before doing repairs or service.
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- Do the battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-510451-S08643886292012102300000) ).
- Disconnect the front receiver line and front suction line from the front evaporator core (see «FRONT EVAPORATOR CORE REPLACEMENT»(ref-510445-S41210150842012102300000) ).
- When the engine is cool, drain the engine coolant from the radiator (see «COOLANT CHECK»(ref-510438-S26925506222012102300000) ).
- Front under the hood, remove the clamp (A). Slide the hose clamps (B) back. Then disconnect the inlet heater hose (C) and the outlet heater hose (D) from the heater unit. Note the layout of the hose. Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on the electrical parts or the painted surfaces. If any coolant spills, rinse it off immediately.
- Remove the mounting nuts from the heater unit. Take care not to damage or bend the fuel lines or brake lines, etc.
- Remove the dashboard (see «DASHBOARD REPLACEMENT»(ref-510494-S29628406722012102300000) ).
- Disconnect the connector (A) from the front blower motor. Detach the wire harness clips (B).
- Disconnect the connector (A) from the headlight leveling control unit, then detach the harness clip (B).
- Disconnect the connectors (A) from the front mode control motor, the passenger's air mix control motor, the recirculation control motor, and the front power transistor. Detach the wire harness clips (B).
- Disconnect the connectors (A) from the driver's air mix control motor and the front evaporator temperature sensor. Detach the wire harness clips (B), then remove the wire harness (C).
- Turn over the carpet. Detach the wire harness clips (A) and the rear heater duct mounting clips (B), then remove the rear heater duct (C).
- Remove the mounting nuts. Slide the blower-heater unit (A), then remove the drain hose (B) and blower-heater unit.
- Remove the self-tapping screws and the passenger's heater duct (A). Remove the self-tapping screws and the expansion valve cover (B). Remove the self-tapping screw and the front heater core cover (C). Remove the self-tapping screws, the heater pipe brackets (D), the grommets (E), and carefully pull out the front heater core (F).
- Install the front heater core, and the front evaporator core in the reverse order of removal.
- Install the heater unit in the reverse order of removal, and note these items: Do not interchange the inlet and outlet heater hoses, and install the hose clamps securely. Refill the cooling system with engine coolant (see «COOLANT CHECK»(ref-510438-S26925506222012102300000) ). Make sure that there is no coolant leakage. Make sure that there is no air leakage. Refer to the front evaporator core replacement (see «FRONT EVAPORATOR CORE REPLACEMENT»(ref-510445-S41210150842012102300000) ).
- Do the battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-510451-S08643886292012102300000) ).
- After installation, operate the heater unit in various functions to confirm that it works properly.
- Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO CHECK FOR DTCS WITH THE HDS»(ref-510445-S07680172972012102300000) ).
Scheme 84
- Remove the driver's dashboard undercover (see «DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION»(ref-510494-S20870098072012102300000) ).
- Disconnect the 7P connector (A) from the driver's air mix control motor (B). Remove the self-tapping screws and the driver's air mix control motor from the heater unit.
- With the motor removed, make sure the door linkage moves smoothly and does not bind.
- Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.
Scheme 85
- Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-510494-S12847216142012102300000) ).
- Disconnect the 7P connector (A) from the passenger's air mix control motor (B). Remove the self-tapping screws and the passenger's air mix control motor from the heater unit.
- With the motor removed, make sure the door linkage moves smoothly and does not bind.
- Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.
Scheme 86
- Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-510494-S12847216142012102300000) ).
- Disconnect the 7P connector (A) from the front mode control motor (B). Remove the self-tapping screws and the front mode control motor from the heater unit.
- Install the motor in the reverse order of removal. Make sure the pin on the motor is properly engaged with the linkage. After installation, make sure the motor runs smoothly.
Scheme 87
- Remove the glove box (see «GLOVE BOX REMOVAL/INSTALLATION»(ref-510494-S12847216142012102300000) ).
- Disconnect the 7P connector (A) from the recirculation control motor (B). Remove the self-tapping screws and the recirculation control motor from the blower unit.
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- Make sure the damper lever pins in the motor lever are visible through the holes.
- While holding the recirculation control motor (A), install the self-tapping screws and connect the 7P connector (B).
- After installation, make sure the motor runs smoothly.
Scheme 90
- Remove the driver's dashboard lower cover (see «DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION»(ref-510494-S20870098072012102300000) ).
- Remove the humidity/in-car temperature sensor (A) from the driver's dashboard lower cover (B).
- Install the sensor in the reverse order of removal. Be sure to connect the air hose securely.
Scheme 91
- Remove the bulkhead cover (see «FRONT BULKHEAD COVER REPLACEMENT»(ref-510464-S28339333712012102300000) ).
- Lift the tab (A) to release the lock, then remove the outside air temperature sensor (B) from the back of the front bumper. Disconnect the 2P connector (C) from the outside air temperature sensor.
- Install the sensor in the reverse order of removal.
Scheme 92
- Remove the sunlight sensor (A) from the dashboard, then disconnect the 5P connector (B). Be careful not to damage the sensor and the dashboard.
- Install the sensor in the reverse order of removal.
Scheme 93
- Remove the driver's dashboard undercover (see «DRIVER'S DASHBOARD LOWER COVER REMOVAL/INSTALLATION»(ref-510494-S20870098072012102300000) ).
- Remove the TPMS control unit (see «TPMS CONTROL UNIT REPLACEMENT»(ref-510482-S09826409242012102300000) ).
- Disconnect the connector (A) from the front evaporator temperature sensor (B), then detach the connector clip (C). Remove the self-tapping screw and the front evaporator temperature sensor.
- Install the sensor in the reverse order of removal.
Scheme 94
- Remove the audio unit (see «AUDIO UNIT REMOVAL/INSTALLATION»(ref-510484-S38675893192012102300000) ) or audio-navigation unit (see «AUDIO-NAVIGATION UNIT REMOVAL/INSTALLATION»(ref-510512-S04174865142012102300000) ).
- Remove the self-tapping screws, and remove the climate control unit (A) from the audio-navigation unit.
- Install the control unit in the reverse order of removal. After installation, operate the climate control unit in various functions to confirm that it works properly.
- Run the self-diagnostic function to confirm that there are no problems in the system (see «HOW TO USE THE SELF-DIAGNOSTIC FUNCTION WITHOUT THE HDS»(ref-510445-S26460383912012102300000) ).