Service Manual2005 MAINTENANCE AND REPAIR

Evanda

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

GENERAL A/C SYSTEM SERVICE PROCEDURES

O-ring Replacement

Important : Even though O-rings may look identical, it is extremely important that only recommended service replacement air conditioning O-rings be used or excessive leakage of refrigerant may occur.

Important : Always slip the O-ring onto the flange tube to ensure proper locating and sealing.

Install new Daewoo-approved service replacement air conditioning (A/C) O-rings whenever a joint or a fitting is disassembled, except when the O-rings are provided on new components.

When replacing O-rings on an A/C component or a joint connection, the fitting design should be identified to ensure installation of the correct air conditioning service replacement O-ring. Some joint connections and components will implement a "captured" O-ring design fitting that uses a groove to retain the O-ring. Others do not have a groove and use a "non-captured" or "standard" O-ring. Assembly and tightening procedures are the same for both designs, but the O-rings are different.

Notice : Before installation, verify that both O-rings and fittings have not been nicked or deformed. Deformed or nicked parts must be replaced. Failure to use the proper service replacement parts and procedures may result in excessive refrigerant leakage.

Handling Refrigerant

Caution : Always work in a well-ventilated area and avoid breathing any refrigerant fumes. If you have difficulty breathing, seek medical attention immediately. If refrigerant comes in contact with any part of your body, flush the exposed area with water. If a rash or pain develops, seek medical attention.

Air conditioning systems contain refrigerant. This is a chemical mixture which requires special handling procedures to avoid personal injury.

Always wear goggles and wrap a clean cloth around the fittings, the valves and the connections when performing work that involves opening the refrigerant system. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components.

All refrigerant drums are shipped with a heavy metal screw cap. The purpose of the cap is to protect the valve and the safety plug from damage. It is good practice to replace the cap after each use of the drum.

If it is necessary to transport or carry any container of refrigerant in a vehicle, do not carry it in the passenger compartment.

Handling of Refrigerant Lines and Fittings

Notice : Using too low or too high torque when tightening a fitting can result in loose joints or deformed joint parts. Both conditions can result in refrigerant leakage.

Keep all metal tubing lines free of dents or kinks. Any line restrictions will cause the loss of system capacity.
Never bend a flexible hose line to a radius of less than four times the diameter of the hose.
Never allow a flexible hose line to come within 65 mm (2-1/2 inches) of the exhaust manifold.
Inspect flexible hose lines regularly for leaks or brittleness.
Replace flexible hose lines with new lines if you find signs of deterioration or leaking.
Discharge the refrigeration system of all refrigerant before disconnecting any fitting in the refrigeration system.
Proceed very cautiously regardless of the gauge readings.

Caution : Keep your face and your hands away from the fitting so that you will not be injured if there happens to be liquid refrigerant in the line.

Open the fittings very slowly.
If you notice pressure when you loosen a fitting, allow the pressure to bleed off as described under "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Cap or tape any refrigerant line immediately after it is opened. This will prevent the entrance of moisture and dirt, which can cause internal compressor wear or plugged lines in the condenser, the evaporator core, the expansion valve, or the compressor inlet screens.

Important : Use two proper wrenches to connect the O-ring fittings.

Back up the opposing fitting to prevent distortion of the connecting lines or the components.
Back up both the swagged fitting on the flexible hose connections and the coupling to which it is attached with two wrenches to prevent turning the fitting and damaging the ground seat.
Keep the O-rings and the seats in perfect condition. A burr or a piece of dirt may cause a refrigerant leak.
Dip new O-rings in clean polyalkaline glycol refrigerant oil before installation.

Maintaining Chemical Stability In the Refrigeration System

The efficient operation and the life of the air conditioning (A/C) system is dependent upon the chemical stability of the refrigeration system. When foreign materials, such as dirt, air, or moisture, contaminate the refrigeration system, they will change the stability of the refrigerant and the polyalkaline glycol (PAG) compressor oil. They will also affect the pressure-temperature relationship, reduce efficient operation, and can possibly cause interior corrosion and abnormal wear of moving parts.

Observe the following practices to ensure chemical stability in the system:

Wipe away dirt or oil at and near any connection before opening that connection. This will reduce the chance of dirt entering the system.
Cap, plug, or tape both sides of a connection as soon as possible after opening the connection. This will prevent the entry of dirt, foreign material, and moisture.
Keep all tools clean and dry, including the manifold gauge set and all replacement parts.
Use a clean and dry transfer device and container to add polyalkaline glycol refrigerant oil. This will ensure that the oil remains as moisture-free as possible. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Have everything you need ready to allow you to perform all operations quickly when opening an A/C system. Do not leave the A/C system open any longer than necessary.
Evacuate and recharge any A/C system that has been opened. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section for the instructions to perform this procedure properly.

All service parts are dehydrated and sealed before shipping. They should remain sealed until just before making connections. All the parts should be at room temperature before uncapping. This prevents condensation of moisture from the air from entering the system. Reseal all parts as soon as possible.

Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System

Caution : Use only refillable refrigerant tanks that are authorized for the charging station being used. The use of other tanks may cause personal injury or void the warranty. Refer to the manufacturer's instructions for the charging station.

Caution : To avoid personal injury, always wear goggles and gloves when performing work that involves opening the refrigeration system.

A charging station discharges, evacuates, and recharges an air-conditioning (A/C) system with one hookup. Filtering the refrigerant during the recovery cycle together with filtering during the evacuation cycle ensures a supply of clean, dry refrigerant for A/C system charging.

Notice :

Never use the R-134a charging station on a system charged with R-12. The refrigerants and the oils from each system are not compatible with those from the other system and must never be mixed, even in the smallest amount. Mixing refrigerant residue will damage the equipment.

Never use adapters which convert from one size fitting to another. Such use allows contamination, which may cause system failure.

Charging Station Setup and Maintenance

There are many charging stations available. All perform the various tasks required to discharge the system and recover refrigerant, evacuate the system, add a measured amount of oil, and recharge an A/C system with a measured amount of refrigerant. Refer to the manufacturer's instructions for all initial setup procedures and all maintenance procedures.

Control Panel Functions

A charging station will have controls and indicators to allow the operator to control and monitor the operation in progress. Refer to the manufacturer's instructions for details. These can be expected to include the following:

Main Power Switch

Supplies electrical power to the control panel.

Display

Shows the time programmed for vacuum.
Shows the weight of the refrigerant programmed for recharging.
Refer to the manufacturer's instructions for detailed programming information.

Low-Side Manifold Gauge

Shows the system's low-side pressure.

High-Side Manifold Gauge

Shows the system's high-side pressure.

Controls Panel

Controls the various operating functions.

Low-Side Valve

Connects the low side of the A/C system to the unit.

Moisture Indicator

Shows whether the refrigerant is wet or dry.

High-Side Valve

Connects the high side of the A/C system to the unit.

Refrigerant Recovery

Important : Use only a refrigerant tank that is designed for the charging station in use. The unit's overfill limitation mechanism is calibrated specifically for use with this tank. The tank's valves are also manufactured specifically for this unit.

Attach the high-side hose with the quick disconnect coupler to the high-side fitting of the vehicle's A/C system.
Open the coupler valve.
Attach the low-side hose with the quick disconnect coupler to the low-side fitting of the vehicle's A/C system.
Open the coupler valve.
Check the high-side and the low-side gauges on the unit's control panel in order to ensure that the A/C system has pressure. If there is no pressure, there is no refrigerant in the system to recover.

Important : If there is no refrigerant in the system, do not continue with the recovery operation which would, under this condition, draw air into the recovery tank.

Open both the high-side and the low-side valves.
Open the gas and the liquid valves on the tank.
Drain any oil that may be in the oil separator.
Close the oil drain valve.
Plug the unit into the proper voltage outlet.
Turn on the main power switch.

Notice : Never reuse refrigerant oil. Damage to the A/C system may result from such reuse. Dispose of the refrigerant oil properly.

Begin the recovery process. Refer to the manufacturer's instructions for the charging station in use.

Important : Some A/C system polyalkaline glycol (PAG) lubricating oil may be removed with the refrigerant during recovery. The amount of oil removed varies. A charging station separates the oil from the refrigerant and provides a means of determining how much oil was removed. Replace the same amount of oil when recharging the system. Refer to the manufacturer's instructions for the charging station in use.

Wait 5 minutes, then check the control panel low-side gauge. If the A/C has maintained vacuum, the recovery is complete.
If the low-side gauge pressure rises above zero, there is more refrigerant in the system. Recover the additional refrigerant. Repeat this step until the system maintains vacuum for 2 minutes.

Important : If the control indicator shows that the refrigerant tank is full during the recovery process and the unit shuts off, install an empty unit tank to store the refrigerant needed for steps later in the procedure. Do not use any other type of tank.

Evacuation

The unit tank must contain a sufficient amount of R-134a refrigerant for charging. Check the amount of refrigerant in the tank. If there is less than 3.6 kg (8 pounds) of refrigerant, add new refrigerant to the tank. Refer to the manufacturer's instructions for adding refrigerant.

Verify that the high-side and the low-side hoses are connected to the A/C system. Open both the high-side and the low-side valves on the unit's control panel.
Open both the gas and the liquid valves on the tank.

Important : Refer to the manufacturer's instructions for the charging station in use. It is necessary to evacuate the system before recharging it with new or recycled refrigerant.

Start the vacuum pump and begin the evacuation process. Non-condensable gases (mostly air) are vented from the tank automatically during the recycling process. You may hear the pressure being released.
Check for leaks in the system. Refer to the manufacturer's instructions for the charging station in use.

Important : Change the vacuum pump oil frequently. Refer to the manufacturer's instructions for the charging station in use.

A/C System Oil Charge Replenishing

Any oil removed from the A/C system during the recovery process must be replenished at this time.

Use the correct graduated bottle of PAG oil for the R-134a system.
Use the correct graduated bottle of PAG oil for the R-134a system.

Important:

Keep the oil bottles tightly capped at all times to protect the oil from moisture and contamination.
You must have an A/C system vacuum for this operation. Never open the oil injection valve while there is positive pressure in the A/C system. This will result in oil blowback through the bottle vent.
Never let the oil level drop below the pickup tube while charging or replenishing the system, as this will allow air into the A/C system.

Refer to the manufacturer's instructions for the charging station in use. Add the proper amount of PAG oil to the system.
Close the valve when the required oil charge has been pulled into the system.

Charging

Important : Evacuate the A/C system before charging.

Close the low-side valve on the control panel.
Open the high-side valve on the control panel.
Refer to the manufacturer's instructions for the charging station in use.
Enter the amount of refrigerant needed to charge the A/C, making sure to use the correct system of measurement, i.e. kilogram (kg) or pound (lb).
Begin the charging process.

Successful Transfer Complete

Close the high-side valve on the unit's control panel. Both valves should be closed.
Start the vehicle and the A/C system.
Let the engine run until the readings on the high-side gauge and the low-side gauge stabilize.
Compare the readings to the system specifications.
Check the evaporator outlet temperature to ensure that the A/C system is operating within the system specifications.
Keep the A/C running.
Close the high-side coupler valve.
Disconnect the high-side hose from the vehicle.
Open the high-side and low-side valves on the control panel. The system will quickly draw in refrigerant from both hoses through the low-side hose.
Close the low-side coupler valve.
Disconnect the low-side hose from the vehicle.

Unsuccessful Transfer

Sometimes the total charge does not transfer into the A/C system. There are two reasons why this may occur:

The pressure in the unit's tank and the pressure in the A/C system are roughly equal.

This will cause the transfer to proceed too slowly.
Refer to the manufacturer's instructions for the charging station in use.

There was not enough refrigerant in the unit's tank to transfer the full charge.

It is necessary to recover the partial charge of refrigerant from the vehicle and then evacuate the A/C system and charge it again.
Refer to the manufacturer's instructions for the charging station in use.

SERVICEABLE COMPONENTS

Components Used In Non-A/C Systems

Refer to Section 7A, Heating and Ventilation System for on-vehicle service procedures for the following sections:

Blower Motor.
Blower Resistor.
Control Assembly Knob Lighting.
Control Assembly.
Heater Hoses.
High-Blower Relay.
A/C Control Vacuum Tank.
Temperature Control Cable.

A/C Pressure Transducer

Removal Procedure

Disconnect the negative battery cable.
Release the connector lock and pull the transducer wire connector out.

Remove the transducer with a wrench.
Discard the O-ring seal.

Installation Procedure

Install the new O-ring seal on the transducer.
Install the pressure transducer.

Tighten

Tighten the pressure transducer to 7 N•m (62 lb-in).

Connect the wire connector.
Connect the negative battery cable.

A/C Compressor Relay

Removal Procedure

Disconnect the negative battery cable.
Pull the relay straight up and out from its location in the engine fuse block at the left front corner.

Installation Procedure

Align the relay terminal contacts with the base receptacle.
Push the relay into the base until it is seated.
Connect the negative battery cable.

Air Filter

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

Remove the hood weather strip.
Remove the cowl panel. Refer to Section 9D, Wipers/Washer System.
Remove the air filter cover.

Remove the air filter.

Installation Procedure

Install the air filter into its cavity in the fire wall.

Align the fins on the plastic frame of the filter with the grove in the holder before attempting to insert the filter into place.

Install the air filter cover.
Install the cowl panel with the screws.
Install the hood weather strip.

A/C Expansion Valve

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

Remove the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.

Remove the expansion valve bolts.
Remove the expansion valve.
Remove the O-rings from the evaporator lines.

Installation Procedure

Clean the O-ring surface areas of dirt or contamination.
Install the new O-rings on the evaporator lines.
Install a new expansion valve onto the evaporator lines.
Insert the expansion valve bolts through the expansion valve into the mount surface of the evaporator flange.

Tighten

Tighten the expansion valve bolts to 10 N•m(89 lb-in).

Install the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.

Tighten

Tighten the suction hose and the liquid evaporator pipe retaining nuts to 10 N•m(89 lb-in).

A/C Module

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

Disconnect the negative battery cable.
Remove the instrument panel carrier assembly. Refer to Section 9E, Instrumentation/Driver Information.
Drain the cooling system. Refer to Section 1D, Engine Cooling.
Recover the refrigerant. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.

Remove the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.

Loosen the clamp bolts from the suction hose and the liquid evaporator pipe to allow movement of the hose and the pipe.
Remove the evaporator drain hose.
Compress the heater hose clamps at the fire wall and slide the clamps toward the engine.
Remove the two heater hoses from the core lines at the fire wall.
Remove the screws that secure the A/C module to the fire wall on either side of the heater hoses.

Remove the A/C module screw, that is located above the fuel filter, from the engine compartment side of the fire wall.
Have an assistant support the A/C module from inside the vehicle.

Remove the A/C module screws from the evaporator flange on the engine compartment side of the fire wall. The A/C module will start to drop.
Pull the case straight away from the fire wall.
Remove the A/C module from the vehicle.

Installation Procedure

Position the A/C module in the vehicle.

Notice : To avoid damaging the heater core tubes, make sure they do not contact the fire wall opening.

Slowly raise the A/C module into position and hold it against the fire wall while the screws are installed and tightened from the engine side of the fire wall.
Align and install the A/C module screws above the fuel filter and at the evaporator flange.

Tighten

Tighten the A/C module screws to 8 N•m (71 lb-in).

Install the A/C module screws adjacent to the heater hoses.

Tighten

Tighten the A/C module screws to 8 N•m (71 lb-in).

Install the evaporator drain hose.

Install the two heater hoses.
Slide the heater hose clamps into position.
Remove the instrument panel carrier assembly. Refer to Section 9E, Instrumentation/Driver Information.

Install new O-rings on the suction hose and the liquid evaporator pipe at the fire wall and put the pipes back in place.
Install the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.

Tighten

Tighten the suction hose and the liquid evaporator pipe retaining nuts to 10 N•m (89 lb-in).

Fill the cooling system. Refer to Section 1D, Engine Cooling.
Recharge the A/C system. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
Connect the negative battery cable.

A/C High-Pressure Pipe Line

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the nut at the compressor hose connecting block.
Disconnect the electrical connector at the pressure transducer.

Remove the nut at the condenser connecting block.

Remove the high-pressure pipe-to-receiver-dryer connecting block retaining nut.

Remove the surge tank. Refer to Section 1D, Engine Cooling.
Remove the high-pressure pipe-to-evaporator flange connecting block retaining nut.

Remove the bolt and the nut which secure the clamps that hold the high pressure pipe to the vehicle.
Remove the high-pressure pipe from the vehicle.
Cap the opening at the receiver-dryer to prevent contamination.

Installation Procedure

Position the high-pressure pipe into the vehicle.

Install a new O-ring on the pipe at the receiver dryer.
Install the high-pressure pipe-to-receiver-dryer connecting block nut.

Tighten

Tighten the high-pressure pipe-to-receiver-dryer connecting block nut to 14 N•m (10 lb-ft).

Install the high-pressure pipe to-evaporator flauge connecting block retaining nut.

Tighten

Tighten the high-pressure pipe-to-evaporator flauge connecting block retaining nut to 15 N•m (11 lb-ft).

Install the nut at the condenser connecting block.

Tighten

Tighten the condenser connecting block nut to 16 N•m (12 lb-ft).

Install the nut at the compressor hose connecting block.

Tighten

Tighten the compressor hose connecting block nut to 38 N•m (28 lb-ft).

Install the bolt and the nut which secure the clamp that hold the high pressure pipe to the vehicle.
Connect the electrical connector to the pressure transducer.
Install the surge tank. Refer to Section 1D, Engine Cooling.
Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

Heater Core

Removal Procedure

Disconnect the negative battery cable.
Remove the A/C module. Refer to "A/C Module" in this section.
Remove the heater core from the case. Refer to Section 7A, Heating and Ventilation System.

Installation Procedure

Install the heater core into the case. Refer to Section 7A, Heating and Ventilation System.

Install the A/C module. Refer to "A/C Module" in this section.
Fill the cooling system. Refer to Section 1D, Engine Cooling.
Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

Evaporator Core

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

Install the A/C module. Refer to "A/C Module" in this section.
Remove the screws that secure the evaporator case halves.
Remove the evaporator core case cover.
Slide the evaporator flange support plate upward to facilitate the removal of the evaporator.

Remove the evaporator core from the case.
Remove the air conditioning expansion valve. Refer to "A/C Expansion Valve" in this section.

Installation Procedure

Install the O-rings onto the evaporator tubes.
Install the A/C expansion valve. Refer to "A/C Expansion Valve" in this section.

Install the evaporator core into the case. Center the evaporator flange in the case opening.
Assemble the evaporator case halves with the screws.
Install the heater/air distributor case assembly. Refer to "A/C Expansion Valve" in this section.

A/C Suction Hose Assembly

Removal Procedure

Disconnect the negative battery cable.
Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the surge tank mounting screws.
Remove the surge tank.
Remove the retaining nut from the hose connecting block and disconnect the air conditioning (A/C) hose assembly connector block at the top rear of the compressor.
Cap all of the openings to prevent contamination.

Remove the suction hose support clamp bolt and the clamp along the left side of the engine compartment fender well.
Remove the evaporator flange connecting block retaining nut and disconnect the A/C suction hose at the fire wall evaporator flange connecting block. Discard the O-ring seal.
Remove the A/C suction hose.
Cap the opening to the evaporator flange to prevent contamination.

Installation Procedure

Install a new O-ring seal onto the suction hose end at the evaporator flange.
Position the hose assembly and the support clamp in place in the vehicle.
Insert the suction hose end into the evaporator flange.
Install the evaporator flange connecting block retaining nuts.

Tighten

Tighten the suction hose connecting block retaining nuts to 15 N•m (11 lb-ft).

Install new sealing washers onto the pilots of the suction/discharge block fitting. The washers must be seated against the surface of the block fitting.

Mate the discharge hose connecting block to the compressor. Hold it in place while tightening the retaining nut.

Tighten

Tighten the discharge hose connecting block-to-compressor retaining nut to 38 N•m (28 lb-ft).

Install the suction hose support clamp on the left-side strut tower and tighten the support clamp retaining nut.

Tighten

Tighten the suction hose support clamp retaining nut to 5 N•m (44 lb-in).

Install the surge tank. Refer to Section 1D, Engine Cooling.
Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

A/C Discharge Hose-Compressor to Condenser

Removal Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the nut at the compressor hose connecting block.

Remove the nut at the condenser connecting block.
Remove the hose from the vehicle.

Installation Procedure

Install new sealing washers at the compressor connecting block end and a new O-ring at the condenser connecting block end.
Position the hose into the vehicle, and install the nut at the condenser connecting block.

Tighten

Tighten the discharge hose connecting block-to-condenser retaining nut to 16 N•m (12 lb-ft).

Mate the hose connecting the connecting block to the compressor, and install the retaining nut.

Tighten

Tighten the discharge hose connecting block-to-compressor retaining nut to 38 N•m (28 lb-ft).

Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Connect the negative battery cable.

Receiver-Dryer

Removal Procedure

Disconnect the negative battery cable.
Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the high-pressure pipe-to-receiver-dryer connecting block nut and remove the pipe from the receiver-dryer.
Remove the receiver-dryer-to-condenser pipe nut.

Loosen the bolt that secures the receiver-dryer band clamp.

Notice : Hold the receiver-dryer-to-condenser pipe to support it so that the pipe is not damaged while being removed from the receiver-dryer.

Remove the receiver-dryer by sliding it up and out of the band clamp.
Cap all open connections to prevent contamination.
Drain the oil from the receiver-dryer into a graduated container. Record the amount of oil drained.
Discard the used oil.

Installation Procedure

Important : Do not uncap the new receiver-dryer until just prior to installation.

Add the new oil to the new receiver-dryer. Use the exact amount of oil that you drained from the old receiver-dryer.
Install new O-rings onto the two pipes that connect to the receiver-dryer.
Install the receiver-dryer into the band clamp. Support the receiver-dryer-to-condenser pipe while pushing the receiver-dryer upward until the pipe is fully installed.
Tighten the bolt on the band clamp.

Tighten

Tighten the band clamp bolt to 5 N•m (44 lb-in).

Install the high-pressure pipe into the receiver-dryer.
Install the high-pressure pipe-to-receiver-dryer connecting block nut.

Tighten

Tighten the high-pressure pipe-to-receiver-dryer connecting block nut to 10 N•m (89 lb-in) and the receiver-dryer-to-condenser pipe nut to 14 N•m (10 lb-ft).

Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

Compressor

Removal Procedure

Disconnect the negative battery cable.
Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the discharge hose mounting nut.
Lift the discharge hose mounting block and the suction hose from the compressor.

Raise and suitably support the vehicle.
Disconnect the electrical connector at the compressor.
Remove the drive belt and the idler pulley. Refer to Section 6B, Power Steering Pump.
Remove the front and the rear compressor-to-bracket bolts.
Remove the compressor.
Drain the oil from the compressor into a container. Measure the amount of the oil that is drained. Then discard the used oil.

Installation Procedure

Add oil to the new compressor. Use the exact amount of oil that you drained from the old compressor.
Install the compressor.
Install the compressor-to-bracket mounting bolts.

Tighten

Tighten the front compressor-to-bracket mounting bolts to 35 N•m (26 lb-ft).

Tighten the rear compressor-to-bracket mounting bolts to 20 N•m (15 lb-ft).

Install the idler pulley and the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.

Install new sealing washers to the suction hose and the discharge hose mounting.
Connect the electrical connector at the compressor.
Lower the vehicle.
Place the suction hose into its cavity in the compressor and install the discharge hose mounting block to clamp it into place. Hold this all together while tightening the retaining nut.

Tighten

Tighten the discharge hose connecting block-to-compressor retaining nut to 33 N•m (24 lb-ft).

Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

Condenser

Removal Procedure

Disconnect the negative battery cable.
Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the radiator. Refer to Section 1D, Engine Cooling.
Remove the discharge hose connecting block-to-condenser retaining nut.
Remove the hose from the condenser.

Remove the high-pressure pipe-to-receiver-dryer connecting block nut.
Remove the pipe from the receiver-dryer.

Remove the upper condenser mount nuts.
Tilt the condenser to the rear, away from the radiator mount support.
Lift the condenser up and out of the engine compartment.
Cap all the open lines and the fittings to prevent contamination.

Installation Procedure

Make sure the condenser rubber mounts are in place.
Install the condenser into the vehicle. The lower mount shock protectors must fit into the holes provided.
Move the condenser forward into the radiator support mount holes.
Install the upper condenser mount nuts and the washers.

Tighten

Tighten the upper condenser mount nuts to 4 N•m (35 lb-in).

Install a new O-ring onto the high-pressure pipe mounting block fitting on the receiver-dryer.
Install the high-pressure pipe into the receiver-dryer.
Install the high-pressure pipe-to-receiver-dryer connecting block nut.

Tighten

Tighten the high-pressure pipe-to receiver-dryer connecting block nut to 10 N•m (89 lb-in).

Install a new O-ring onto the discharge hose connecting block fitting.
Install the discharge hose fitting into the condenser.
Install the discharge hose connecting block-to-condenser retaining nut at the condenser connecting block.

Tighten

Tighten the discharge hose connecting block-to-condenser nut to 16 N•m (12 lb-ft).

Install the radiator. Refer to Section 1D, Engine Cooling.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Connect the negative battery cable.
Operate the HVAC control to verify the proper function of the heating and cooling systems.