REMOVAL & INSTALLATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Disconnect negative battery cable. Remove bolts retaining radio and A/C control assembly to instrument panel. Separate radio from A/C control assembly. To install, reverse removal procedure.
- Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain coolant. Disconnect cable from water valve. Disconnect hoses from heater core.
- Remove instrument panel and brace. Remove blower unit. Disconnect and cap refrigerant lines. Remove rear air ducts. Remove heater protector plate. Remove A/C unit.
- To install, reverse removal procedure. Refill cooling system. Evacuate and recharge A/C system. Start engine. Check for coolant and refrigerant leaks.
Disconnect negative battery cable. Remove glove box. Remove relay block No. 6. Remove air duct. Remove engine control module and bracket. Unplug servomotor connector. Remove servomotor. To install, reverse removal procedure.
Disconnect negative battery cable. Remove dashboard lower finish panel, safety pad, and air duct. Unplug servomotor connector. Remove servomotor. Disconnect control cable. To install, reverse removal procedure.
Disconnect negative battery cable. Remove dashboard lower finish panel, safety pad, and air duct. Unplug servomotor connector. Remove servomotor. To install, reverse removal procedure.
Disconnect negative battery cable. Remove lower dashboard panel and undercover. Remove connector bracket. Remove blower motor. To install, reverse removal procedure.
Remove the following
- Right side cowl side trim.
- Right side front door scuff plate.
- No. 2 instrument panel under cover.
- Lower panel.
- Finish upper panel.
- CD changer assembly.
- Audio amplifier.
- ECM
- Remove connector bracket set screws.
- Remove blower unit.
Disconnect the connectors from blower unit. Disconnect the wire harness clamps. Disconnect the evaporator temp. sensor connector clamp. Remove the 2 screws, bolt and nut, then remove the blower unit.
To install, reverse removal procedure.
- If compressor runs, idle engine for 10 minutes with A/C on. Turn ignition off. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Unplug compressor connector.
- Disconnect refrigerant hoses from compressor. Cap openings. Loosen drive belt. Remove compressor bolts and compressor. To install, reverse removal procedure. Evacuate and recharge system. Test system for leaks.
- Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove battery, upper cover, and radiator fan. Disconnect and plug refrigerant lines at condenser.
- Remove headlights. Pull condenser upward from between radiator and body. To install, reverse removal procedure. Evacuate and recharge system. Inspect system for leaks.
- Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove the blower unit. See «BLOWER UNIT»(ref-36442-S42853031292003092300000). Disconnect and plug refrigerant lines from evaporator assembly. (Scheme 6)
- Disconnect the connector. Remove the screw and pull out the evaporator temp. sensor. Remove the screws and evaporator cover. (Scheme 7) Pull out the evaporator.
- To install, reverse removal procedure. Evacuate and recharge system. Inspect system for leaks.
Scheme 6
Scheme 7
- Remove the evaporator core. See «EVAPORATOR»(ref-36442-S13311190312001010900000).
- Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator and tube. (Scheme 8) NOTE: At the time of installation, lubricate 4 new O-rings with compressor oil and install the tube and valve. Do not reuse the evaporator cover. NOTE: If evaporator is replaced, add compressor oil to evaporator. See «A/C SYSTEM SPECIFICATIONS»(ref-36442-S18624464602001010900000).
- Installation is in the reverse order of removal. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant.
Scheme 8
- Disconnect negative battery cable. Remove A/C unit. See «A/C UNIT»(ref-36442-S41012360122001010900000) . Remove heater core.
- To install, reverse removal procedure. Refill cooling system. Evacuate and recharge system. Start and warm engine to operating temperature. Inspect system for leaks.
Disconnect negative battery cable. Remove dashboard lower finish panel, safety pad, accelerator pedal bracket, and air duct. Unplug power transistor connector. Remove power transistor. To install, reverse removal procedure.
Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect and plug refrigerant lines from receiver-drier. Remove receiver-drier. To install, reverse removal procedure. Evacuate and recharge system. Inspect system for leaks.