A/C Accessory Assembly - Installation Procedures A and B

Air Conditioner Accessory Assembly:

Please select the appropriate installation procedure from the chart shown.

Components

Installation Procedure A

1. Remove Defroster Nozzle Assembly.

A. Remove the clip.

B. Disengage the 2 claws and remove the defroster nozzle assembly.

2. Remove Air Conditioning Amplifier Assembly.

A. Disconnect the connector.

B. Remove the 2 screws and air conditioning amplifier assembly.

NOTE:
Do not remove the air conditioning amplifier bracket, as the air conditioning amplifier and bracket will be reused.

3. Remove Cooler Wiring No. 2.

A. Remove the 5 screws and the cooler wiring No. 2.

NOTE:
^ Remove the brackets from the connector and reinstall them to the heater radiator assembly, as the brackets will be reused.

^ Cut the wire harness in the switch area, and remove the cooler wiring No. 2 from the heater unit.

4. Install New Max Cool Switch and Max Hot Switch.

A. Remove the 2 screws and the new max cool switch from the bracket.

B. Remove the connector from the bracket.

C. Install the new max hot switch on the heater radiator assembly with the 2 original screws.

D. Install the new max cool switch with one new screw.

E. Install the connector to the switch base as illustrated.

HINT:
Only one screw is used to secure the max cool switch.

5. Install New Cooler Wiring No. 2.

A. Route the foot defrost switch around the back side of the defroster nozzle, and install it with the 2 screws.

B. Place the new cooler wiring No. 2 as shown in the illustration.

C. Connect the connector.

6. Install Air Conditioning Amplifier.

A. Reinstall the air conditioning amplifier assembly removed in step 2.

B. Connect the connector.

7. Check Operation.

A. Install the instrument cluster finish panel sub-assembly.

B. Remove the glove compartment door assembly.

C. Reconnect the battery, and then turn the ignition switch ON.

D. Set up the following:

^ Fresh Mode

^ Blower Low

^ Face

E. Check the door inside the blower motor cover when the temperature control knob is in the MAX COOL position. The door should be OPEN.

F. Move the temperature control knob from the MAX COOL position towards the MAX HOT direction by 3 to 4 notches, and then check the door inside the blower motor cover. The door should be CLOSED.

G. Remove the instrument cluster finish panel sub-assembly.

H. Turn the ignition switch OFF, and then disconnect the battery.

NOTE:
Confirm the adjustment of air mix cable by referring to TSB No. AC002-04, "A/C Not Cold Enough."

8. Reassemble Instrument Panel Sub-assembly.

Installation procedure B

1. Remove Defroster Nozzle Assembly.

A. Remove the clip.

B. Disengage the 2 claws and remove the defroster nozzle assembly.

2. Remove Air Conditioning Amplifier Assembly.

A. Disconnect the connector.

B. Remove the 2 screws and air conditioning amplifier assembly.

NOTE:
Remove the air conditioning amplifier bracket, as only the air conditioning amplifier will be reused.

3. Remove Air Mix Damper Control Cable Sub-assembly.

A. Disconnect the outer cable.

B. Disconnect the inner cable and remove the air mix damper control cable sub-assembly.

4. Remove Cooler Wiring No. 2.

A. Remove the 5 screws and the cooler wiring No. 2.

NOTE:
^ Remove the brackets from the connector and reinstall them to the heater radiator assembly, as the brackets will be reused.

^ Cut the wire harness in the switch area, and remove the cooler wiring No. 2 from the heater unit.

5. Replace Air Mix Link.

A. Remove the 2 screws, and remove the air mix main link, air mix sub link, and air mix link shaft.

HINT:
There are 3 kinds of air mix links.

B. Install the new air mix main link.

C. Install the new air mix sub link.

D. Tighten the 2 screws.

E. Install the new air mix link shaft.

HINT:
After installing the air mix link shaft, check that the links move smoothly.

6. Install Air Conditioner Accessory Assembly.

A. Install the air conditioner accessory assembly with the 4 screws.

NOTE:
^ Check that the top ends of the air mix door lever and the max cool switch lever are almost flush.

^ If the top ends of the air mix door lever and the max cool switch lever are not flush, adjust the height by bending the air conditioner accessory assembly bracket.

7. Install New Cooler Wiring No. 2.

A. Route the foot defrost switch around the backside of the defroster nozzle, and install it with the 2 screws.

B. Place the new cooler wiring No. 2 as shown in the illustration.

NOTE:
Fit the wire harness into the boss area indicated with the arrows.

C. Connect the connector.

8. Install Air Conditioning Amplifier.

A. Install the air conditioning amplifier assembly removed in step 2.

B. Connect the connector.

9. Install Air Mix Damper Control Cable Sub-assembly.

HINT:
Adjust the air mix cable by referring to TSB No. AC002-04, "A/C Not Cold Enough."

10. Check Operation.

A. Install the instrument cluster finish panel sub-assembly.

B. Remove the glove compartment door assembly.

C. Reconnect the battery, and then turn the ignition switch ON.

D. Set up the following:

^ Fresh Mode

^ Blower Low

^ Face

HINT:
Move the temperature control knob to the MAX COOL position and then loosen the 2 screws indicated in the illustration. Move the air conditioner accessory assembly bracket to adjust the MAX COOL switch position so the door inside the blower motor cover is open. Tighten the 2 screws once the desired position is achieved.

G. Remove the instrument cluster finish panel sub-assembly.

H. Turn the ignition switch OFF, and then disconnect the battery.

11. Reassemble Instrument Panel Sub-assembly.

12. Warm Up Engine.

13. Inspect Leakage of Refrigerant.