Air Conditioning Unit (For Hatchback) Installation

Engage the 3 claws and install the air duct.

Engage the 3 claws and install the air duct.

Install the cooler air hose.

Install the air conditioning radiator with the 3 screws.

Engage the claw and install the air conditioning amplifier as shown in the illustration.

Tighten the screw.

Temporarily tighten the air conditioning unit with the 3 bolts and nut.

NOTICE:

To prevent damage to the installation bracket for the air conditioning unit, be sure to support the air conditioning unit in place.

Install the instrument panel reinforcement with the 8 bolts.

Engage the 2 claws and install the rear No. 1 air duct.

Install the instrument panel brace with the 2 bolts, nut and screw.

HINT:

If the vehicle is equipped with knee airbag, install the knee airbag bracket mounting bolt.

Install the air duct with the 2 bolts.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the bolt, nut and 4 screws in the order shown in the illustration.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}for bolt

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}for nut

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}for screw 1, 2, 3

Connect the connectors and engage the clamps, then install the instrument panel wire.

Install the ground wire with the bolts.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Engage the 3 clamps and install the instrument panel wire.

Connect the 3 connectors.

Connect the 3 clamps and install the connector holders.

Tighten the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the connectors.

Install the wire harness protector with the screw.

Connect the 2 clamps and install the connector holders.

Tighten the screw.

Connect the connectors.

Connect the 2 clamps.

for Cold Area Specification Vehicles:

1. Install the ground wire with the bolt.
   

   Torque:

   8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the back side connectors and install the instrument panel junction block as shown in the illustration.

NOTICE:

Securely connect the connector.

Install the instrument panel junction block with the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Connect the front side connectors as shown in the illustration.

NOTICE:

Securely connect the connector.

Engage the clamps.

Install the drain cooler hose as shown in the illustration.

NOTICE:

1. Install the drain hose with its UP mark facing upward, within the 60 degree range shown in the illustration.
   
2. Install the drain hose without twisting it.
   

Install the 2 claws and install the air duct.

Install the 2 claws and install the air duct.

Install the 2 claws and install the air duct.

Return the floor carpet.

Engage the 2 claws and 3 guides, then install the defroster nozzle.

Engage the clamps and connect the connectors, then connect the wire harness.

Engage the 3 claws and install the heater to register duct.

Connect the heater water inlet hose onto the air conditioning unit.

HINT:

Perform the installation with the hose clip and mark at the correct angle.

Connect the heater water outlet hose onto the air conditioning unit.

HINT:

Perform the installation with the hose clip and mark at the correct angle.

Remove the vinyl tape from air conditioner tube, liquid tube and the connecting portion of the unit.

Apply sufficient compressor oil (ND-OIL8) to 2 new O-rings and the connecting part of the air conditioner tube and liquid tube.

Compressor oil:

ND-OIL8 or equivalent

Install the 2 O-rings onto the air conditioner tube and liquid tube.

Securely connect the air conditioner tube and liquid tube to the air conditioning unit.

Turn the hook connector in the direction indicated by the arrow in the illustration.

Insert the pipe joints securely into the fitting holes and tighten the bolt.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the outer cowl top panel with the 8 bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Engage the 2 clamps and install the wire harness.

Install the cowl top to cowl brace with the 2 bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Engage the clip and install the front No. 1 ventilator seal.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

SST

09985-20010(09985-02010,09985-02050,09985-02060,09985-02070,09985-02080,09985-02090,09985-02110,09985-02130,09985-02140,09985-02150)

Standard:

330 to 390 g (11.6 to 13.8 oz.)

NOTICE:

Do not start the engine before charging it with refrigerant as the cooler compressor does not work properly without sufficient refrigerant. This could cause the compressor to overheat.

HINT:

1. The relationship between the refrigerant charge amount and the pressure is as follows.
   
   
   
   
   
   
2. High Charge Range:
   If the refrigerant is overcharged, the pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.
   
3. Low Charge Range:
   A shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens the compressor life. Operation with insufficient coolant raises the refrigerant temperature and causes heat deterioration of the rubber seals and hoses. Cracking and subsequent refrigerant leakage may occur.
   

1. Install the caps onto the service valves on the refrigerant line.
   

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation as follows:

1. Stop the engine.
   
2. Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. Make sure that some refrigerant remains in the refrigeration system.
   When the compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
   

HINT:

It is impossible for the above pressure to be maintained if there is leakage.

Using the halogen leak detector, check the refrigerant line, especially at the connection points, for leakage.

Bring the halogen leak detector close to the drain hose before performing the test.

HINT:

1. After the blower motor has stopped, leave the cooling unit for at least 15 minutes.
   
2. Place the halogen leak detector sensor under the drain hose.
   
3. When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to other volatile gases.
   

If no gas leakage is detected from the drain hose, remove the blower motor from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.