1 AIR CONDITIONING KIT INSTALLATION MANUAL CONTENTS GENERAL INFORMATION 2 CAUTION LABEL 4 COMPRESSOR 5 AIR CONDITIONING KIT INSTALLATION 7 REFRIGERANT CHARGING 13 CODING PROCEDURE 13 PERFORMANCE TEST 15
COMPONENT PARTS Check that there are all the parts below -2 GENERAL INFORMATION GENERAL INFORMATION M5301000100038 AC809178 3 1 2 4 5 AC903491AB 6 7 8 AC701976 10 11 AC903399AB AC701978AB 9 12 14 13 AC701977AB AC701979AB
-3 GENERAL INFORMATION 15 17 AC200079 AD AC809176AD 16 AC703224AB No Part No Quantity Part name 1 7812A204 1 Condenser assembly 2 7815A068 1 Liquid pipe assembly A 3 7815A464 1 Suction flexible hose 4 7815A072 1 Liquid pipe assembly B 5 7815A457 1 Discharge flexible hose 6 MS240121 1 Washer bolt assembly (6 16 mm) 7 MF140203 1 Flange bolt (6 12 mm) 8 MF140205 2 Flange bolt (6 16 mm) 9 MS440502 2 Washer nut assembly 10 MR315798 1 Clip (A) 11 MU481267 1 Clip (B) 12 MU000816 1 Pipe clip 13 7815A093 1 Clamp 14 MN121298 1 Clamp 15 MR958646 1 Caution label 16 7815A680 1 Air conditioning kit installation manual 17 7815A656 1 Clip (C)
-4 CAUTION LABEL CAUTION LABEL M5301000500014 Adhere the caution label in the location shown in the figure About 5 mm (02 in) 15 About 5 mm (02 in) About 5 mm (02 in) AC702134AB
REMOVAL AND INSTALLATION CAUTION If any of the following conditions are met, replace the compressor because its performance and quality cannot be guaranteed The compressor mounted on the vehicle is used for one year or more Oil is leaking from the compressor cap When installing the air conditioning kit after the user has used (driven) the vehicle Remove the engine room under cover before removing the compressor -5 COMPRESSOR COMPRESSOR M5301000800026 When removing the drive belt, remove the bolts of the radiator condenser tank and move the radiator condenser tank to the position where it will not interfere with the drive belt removal When installing the radiator condenser tank, tighten the bolts to the torque below Tightening torque: 12 ± 2 N m (102 ± 22 in-lb) When replacing the compressor, remove the parts in numerical order below As for installation, install the parts in the reverse order to removal 2 1 23 ± 6 N m 17 ± 4 ft-lb AC903422AB Removal steps <<A>> 1 Drive belt >>A<< 2 A/C compressor NOTE: <<A>> indicates that there is a removal service point >>A<< indicate that there are installation service points
-6 COMPRESSOR REMOVAL SERVICE POINT Auto-tensioner <<A>> DRIVE BELT REMOVAL To introduce the serpentine drive system with the drive belt auto-tensioner, the following operations will be required CAUTION To reuse the Drive belt, draw an arrow indicating the rotating direction on the back of the belt using chalk to install the same direction 1 Rotate the pulley bolt of the auto-tensioner counterclockwise with an offset wrench [45, a long offset wrench (5/8 x 11/16 inches) recommended] and insert the hexagon wrench into the auto-tensioner hole to fix the auto-tensioner 2 Remove the drive belt AC506731AD Auto-tensioner L-shaped hexagon wrench Pulley bolt AC511067AC 1 3 INSTALLATION SERVICE POINTS >>A<< A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration Tightening torque: 23 ± 6 N m (17 ± 4 ft-lb) 2 A/C compressor and clutch assembly AC903415AB
Insulating tape Battery cable -7 AIR CONDITIONING KIT INSTALLATION AIR CONDITIONING KIT INSTALLATION Battery ACX00583AF M5301001000034 DANGER After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected WARNING Handle the front impact sensors very carefully, taking care not to drop them They must be replaced if they are dropped Before installing the air conditioning kit, remove the parts in numerical order below REMOVAL 1 8 7 3 5 4 6 2 Removal steps 1 Air cleaner intake duct 2 Headlamp support panel cover 3 Hood latch 4 Air bag sensor bracket 5 Front impact sensor <<A>> 6 Front end upper bar assembly 5 4 AC701895AD Removal steps (Continued) 7 Heat protector 8 Power steering oil reservoir bolts NOTE: <<A>> indicates that there is a removal service point
NOTE : Clamp : Bolt -8 AIR CONDITIONING KIT INSTALLATION Battery REMOVAL SERVICE POINT <<A>> FRONT END UPPER BAR ASSEMBLY REMOVAL Remove the bolts and clamps shown in the figure Then, remove the front end upper bar assembly Front bumper AC702256AB
INSTALLATION <Air conditioning kit> When installing the air conditioning kit, follow the procedure below -9 AIR CONDITIONING KIT INSTALLATION 40 ± 20 N m 35 ± 17 in-lb 11 2 9 11 6 High-pressure Side service valve 13 ± 1 N m 115 ± 8 in-lb 12 16 9 10 ± 2 N m 89 ± 17 in-lb 49 ± 09 N m 43 ± 7 in-lb 1 17 13 7 Low-pressure Side service valve 8 10 1 8 10 4 3 6 12 5 3 7 14 4 9 A/C compressor 8 49 ± 09 N m 43 ± 7 in-lb Heater unit AC809177 13 49 ± 09 N m 43 ± 7 in-lb 18 5 NOTE 2 : O-ring position 14 15 17 10 ± 2 N m 89 ± 17 in-lb AC903496AB Installation steps >>A<< 1 Clip (C) >>B<< 2 Condenser assembly >>A<< 3 Clip (A) >>C<< 4 Liquid pipe assembly B >>A<< 5 Pipe clip >>C<< 6 Suction flexible hose 7 Washer bolt assembly (6 16 mm) 8 Flange bolt (6 12 mm) >>A<< 9 Clamp 10 Flange bolt (6 16 mm) >>A<< 11 Clip (B) >>D<< 12 Liquid pipe assembly A 13 Washer nut assembly Installation steps (Continued) >>A<< 14 Clamp >>C<< 15 Discharge flexible hose 16 Washer nut assembly 17 Flange bolt (6 16 mm) 18 A/C pressure sensor connector NOTE: >>A<<, >>B<<, >>C<< and >>D<< indicate that there are installation service points Remove the resin cap just before the air conditioning kit installation Also check that the O-ring is not damaged or contaminated
Clip (A) -10 AIR CONDITIONING KIT INSTALLATION Power steering oil reservoir INSTALLATION SERVICE POINTS >>A<< CLIPS AND CLAMPS INSTALLATION Install the clips and the clamps as shown in the figure on the left >>B<< CONDENSER ASSEMBLY INSTALLATION Pipe clip Clamp Clip (B) Clip (C) A/C compressor Clamp AC809342AB <Before installation> Radiator Claw Hook Claw When installing the condenser assembly, insert the condenser brackets into the hooks on both sides of the radiator, and fix them with the claws >>C<< LIQUID PIPE ASSEMBLY B/SUCTION FLEXIBLE HOSE/DISCHARGE FLEXIBLE HOSE INSTALLATION When installing pipes or hoses, apply an appropriate amount of compressor oil to the O-ring Hook <After installation> Claw Condenser bracket Hook Radiator AC702200 Condenser assembly >>D<< LIQUID PIPE ASSEMBLY A INSTALLATION Remove the hose of the radiator condenser tank, and install liquid pipe assembly A When installing pipe, apply an appropriate amount of compressor oil to the O-ring Claw Condenser bracket Hook AC809175 AC809346 AB
INSTALLATION <REMOVED PARTS> -11 AIR CONDITIONING KIT INSTALLATION WARNING Handle the front impact sensors very carefully, taking care not to drop them They must be replaced if they are dropped 7 8 13 ± 2 N m 111 ± 22 in-lb 1 90 ± 20 N m 12 ± 1 N m 80 ± 17 in-lb 102 ± 13 in-lb 5 4 90 ± 10 N m 80 ± 9 in-lb 3 12 ± 1 N m 102 ± 13 in-lb Installation steps 1 Heat protector >>A<< 2 Front end upper bar assembly >>B<< 3 Front impact sensor 4 Air bag sensor bracket >>C<< 5 Hood latch 6 Headlamp support panel cover 2 4 3 90 ± 20 N m 80 ± 17 in-lb 6 40 ± 20 N m 36 ± 17 in-lb AC701895AC Installation steps (Continued) 7 Air cleaner intake duct 8 Power steering oil reservoir bolts NOTE: >>A<<, >>B<< and >>C<< indicate that there are installation service points
-12 AIR CONDITIONING KIT INSTALLATION INSTALLATION SERVICE POINTS >>A<< FRONT END UPPER BAR ASSEMBLY INSTALLA- TION When installing the front end upper bar assembly, tighten the bolts shown in the figure to the specified torque Battery >>B<< FRONT IMPACT SENSOR INSTALLATION WARNING The SRS may not activate properly if a front impact sensor is not installed properly, which could result in serious injury or death to the vehicle's driver Position the front impact sensor facing toward the front of the vehicle as indicated by the arrow on the label, and install it securely >>C<< HOOD LATCH INSTALLATION 45 ± 15 N m 40 ± 13 in-lb 50 ± 2 N m 45 ± 17 in-lb 50 ± 2 N m 45 ± 17 in-lb Front bumper 45 ± 15 N m 40 ± 13 in-lb AC702256AD 1 Loosen the hood latch mounting bolts but do not remove them Move the hood latch up/down and left/right to align the hood level and adjust the hood striker engagement 2 After the adjustment, tighten the hood latch mounting bolts to 90 ± 10 N m (80 ±9 in-lb) Hood latch AC608554AB
Item Refrigerant and quantity g (oz) Use the refrigerant recovery station to charge the refrigerant -13 REFRIGERANT CHARGING REFRIGERANT CHARGING Specification R-134a (HFC-134a), 480 520 (169 183) M5301000700018 NOTE: Refer to the Refrigerant Recovery and Recycling Unit s Instruction Manual for operation of the unit Data link connector MB991910 MB991824 MB991827 CODING PROCEDURE AC608435AB M5301000600011 HOW TO CONNECT THE SCAN TOOL (MUT-III) Required Special Tools: MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: Vehicle Communication Interface (VCI) MB991827: MUT-III USB Cable MB991910: MUT-III Main Harness A CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958 1 Ensure that the ignition switch is at the "LOCK" (OFF) position 2 Start up the personal computer 3 Connect special tool MB991827 to special tool MB991824 and the personal computer 4 Connect special tool MB991910 to special tool MB991824 5 Connect special tool MB991910 to the data link connector 6 Turn the power switch of special tool MB991824 to the "ON" position NOTE: When the special tool MB991824 is energized, the special tool MB991824 indicator light will be illuminated in a green color 7 Start the MUT-III system on the personal computer NOTE: Disconnecting the scan tool special tool MB991824 is the reverse of the connecting sequence, making sure that the ignition switch is at the "LOCK" (OFF) position
-14 CODING PROCEDURE OPTION CODING Required Special Tools: MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: Vehicles Communication Interface (VCI) MB991827: MUT-III USB Cable MB991910: MUT-III Main Harness A (Vehicles with CAN communication system) CAUTION If there is any item indicated by the option coding after equipment change, set ETACS-ECU so that the option coding data corresponds with the equipment content Functions and systems do not work normally if the setting does not correspond with the equipment The ETACS-ECU option coding data can be checked or changed by operating scan tool MB991958 How to change option coding data 1 Connect the scan tool MB991958 2 Turn the ignition switch to the "ON" position 3 Select "System select" from the start-up screen 4 Select "From 2006 MY" under "Model Year" Check that "Vehicle Information" contents are correct 5 Select "ETACS" from "System List", and then press "OK" button NOTE: If "Loading Option Setup" list is shown, click appropriate box 6 Select "Coding" 7 Select "Option Coding" 8 Change the compressor type from "No compressor" to "Scroll 90cc"
Low-pressure valve Charging hose (Blue) Adaptor valve (For low-pressure) Adaptor valve (For highpressure) Lowpressure service valve Highpressure service valve -15 PERFORMANCE TEST High-pressure valve Gauge manifold Charging hose (Red) PERFORMANCE TEST A Sleeve AC609415AC Thermometer M5301000900012 The vehicles to be tested should be parked under non-direct sunlight 1 Close the high and low-pressure valve of the gauge manifold 2 Connect the charging hose (blue) to the low-pressure valve and connect the charging hose (red) to the high-pressure valve of the gauge manifold 3 Install the quick joint (for low-pressure) to the charging hose (blue), and connect the quick joint (for high-pressure) to the charging hose (red) CAUTION To connect the quick joint, press section A firmly against the service valve until a click is heard When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose 4 Connect the quick joint (for low-pressure) to the lowpressure service valve and connect the quick joint (for highpressure) to the high-pressure service valve NOTE: The high-pressure service valve is on the A/C pipe and the low-pressure service valve is on the suction hose 5 Start the engine 6 Set the A/C controls as follows: A/C switch: A/C ON position Mode selection: FACE position Temperature control: MAXIMUM COOLING position Air selection: RECIRCULATION position Blower switch: Maximum air volume 7 Set the engine speed to the idle speed 8 Engine should be warmed up with hood, doors and windows opened 9 Insert a thermometer in the center air outlet and operate the engine for 20 minutes NOTE: If the A/C clutch cycles, take the reading before the clutch disengages 10Note the discharge air temperature AC609414AB
PERFORMANCE TEMPERATURE CHART Garage ambient air temperature C ( F) Discharge air temperature C ( F) Compressor high pressure kpa (psi) Compressor low pressure kpa (psi) -16 PERFORMANCE TEST 20 (68) 25 (77) 30 (86) 35 (95) 40 (104) 45 (113) 50 (122) 47 (40) 17 (63) 934 (136) 1,700 (247) 170 (247) 359 (521) 10 (50) 23 (73) 1,068 (155) 1,850 (268) 215 (312) 406 (589) 15 (59) 28 (82) 1,201 (174) 2,000 (290) 260 (377) 452 (656) 20 (68) 33 (91) 1,335 (193) 2,150 (312) 305 (442) 499 (724) 26 (79) 38 (100) 1,468 (213) 2,300 (334) 350 (508) 545 (791) 31 (88) 44 (111) 1,602 (232) 2,450 (355) 395 (573) 592 (859) 36 (97) 49 (120) 1,735 (252) 2,600 (377) 440 (638) 638 (926)