Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE COOL AIR INTAKE DUCT SEAL 3. REMOVE ENGINE ROOM SIDE COVER LH 4. REMOVE ENGINE ROOM SIDE COVER RH 5. DISCHARGE REFRIGERANT FROM REFRIGERATION (a) Start up the engine. (b) Turn the A/C switch on. (c) Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. (d) Stop the engine. (e) Using SST, let the refrigerant gas out. 6. DISCONNECT CABLE FROM NEGATIVE BATTERY CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment 7. REMOVE FRONT UPPER FENDER PROTECTOR LH 8. REMOVE FRONT UPPER FENDER PROTECTOR RH 9. REMOVE ROOF DRIP SIDE FINISH MOULDING LH 10. REMOVE ROOF DRIP SIDE FINISH MOULDING RH 11. REMOVE FRONT WIPER ARM HEAD CAP 12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH 13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH 14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 15. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 16. SEPARATE SUCTION PIPE SUB-ASSEMBLY (a) Remove the bolt, and slide the hook connector. (b) Disconnect the suction pipe sub-assembly. (c) Remove the O-ring from the suction pipe sub-assembly. Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 17. SEPARATE LIQUID TUBE SUB-ASSEMBLY (a) Disconnect the liquid tube sub-assembly. (b) Remove the O-ring from the liquid tube sub-assembly. Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 18. REMOVE HEATER WATER OUTLET HOSE

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Fig. 5: 1. Remove oil felt. Using a screw driver, pry out oil felt. See Fig. 6. 2. Remove key. Using a hammer and punch, drive key from shaft. Disassembly of Compressor See Fig. 7. 3. Remove circlip. Using snap ring pliers, remove circlip. See Fig. 8. 4. Apply compressor oil to inner bore. See Fig. 9. Fig. 6: Removing Oil Felt Fig. 7: Removal of Key from Shaft Fig. 8: Circlip Removal Fig. 9: 5. Remove lip seal using special tool (A). The following explains this removal procedure: a. Fit special tool (A) into the clutch installation boss. See Fig. 10. Compressor Oil Application Special tool (A): 09990-48220 b. Turn special tool (A) until its protrusion engages with the groove provided on lip seal. See Fig. 11. c. Check that special tool (A) goes down slightly when the protrusion and groove are engaged. d. Turn special tool (A) by 30 -60 . e. Pull up on special tool (A) to remove lip seal. See Fig. 12. CAUTION: DO NOT re-use lip seal once it has been removed from the compressor.

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COOLING UNIT REMOVAL Zoom Sized for Print 1. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 3. DISCONNECT SUCTION TUBE AND LIQUID TUBE FROM COOLING UNIT OUTLET FITTING 4. DISCONNECT LIQUID TUBE FROM COOLING UNIT INLET FITTING HINT: Cap the open fittings immediately to keep moisture out of the system.5. 6. 7. 8. REMOVE GROMMETS FROM INLET AND OUTLET FITTINGS REMOVE GLOVE BOX DISCONNECT CONNECTOR REMOVE COOLING UNIT Remove the 4 screws and a nut. Zoom Sized for Print COOLING UNIT INSTALLATION 1. 2. 3. 4. 5. INSTALL COOLING UNIT Install the cooling unit with the 4 screws and the nut. CONNECT CONNECTORS INSTALL GLOVE BOX INSTALL GROMMETS ON INLET AND OUTLET FITTING CONNECT LIQUID TUBE TO COOLING UNIT INLET FITTING Torque: 14 N.m (140 kgf.cm, 10 ft.lbf) CONNECT SUCTION TUBE TO COOLING UNIT OUTLET FITTING Torque: 32 N.m (325 kgf.cm, 24 ft.lbf) IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR Add 40-50 cc (1.4-1.7 fl.oz.) Compressor oil: ND-OIL 8 or equivalent CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY EVACUATE AIR FROM REFRIGERATION SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND INSPECT FOR GAS LEAKAGE Specified amount: 700 ±50 g (24.69 ±1.76 oz.) 6. 7. 8. 9. 10.

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EVAPORATOR REMOVAL AND INSTALLATION REMOVAL SERVICE POINT SUCTION PIPE OR HOSE, DISCHARGE PIPE DISCONNECTION CAUTION: Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapor easily, possibly damaging the condenser and deteriorating performance. Plug the disconnected hose and the evaporator nipple to prevent foreign material from getting into them. INSTALLATION SERVICE POINT >A< EVAPORATOR INSTALLATION When replacing the evaporator, refill it with the specified amount of compressor oil and install it (to the vehicle).

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REMOVAL 1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. 2. Remove engine cover. Refer to “INTAKE MANIFOLD COLLECTOR”. 3. Remove air cleaner assembly, air hose and air duct. Refer to “AIR CLEANER AND AIR DUCT”. 4. Remove mounting bolt from high-pressure flexible hose bracket. 5. Disconnect one-touch joint between high-pressure flexible hose and condenser. a. Set a disconnector (92530-89912) on A/C piping. b. Slide a disconnector upward until it clicks. c. Slide A/C piping upward and disconnect it. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. 6. Remove mounting nuts from high-pressure flexible hose, and then remove high-pressure flexible hose. 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 basically the reverse order of removal. CAUTION: Replace O-ring of high-pressure flexible hose with a new one, then apply compressor oil to it when installing it.