DENSO INTERNA TIONAL AUSTRALIA PTY LTD

MAC-A552/MAC-A553

HOLDEN

JACKAROO

PART NUMBER 9211 3741 (TURBO DIESEL)

9211 3740 (V6 PETROL)

in whole or in part, without the written permission of the publisher.

IMPORTANT NOTICE

INTRODUCTION

This manual has been designed for technicians who are qualified and educated in the proper procedures of vehicle

safety, handling and maintenance; experienced in installation of car air conditioning or who are able to carry out

installation procedures when given instructions by an experienced technician in a supervisory capacity; and are

certified to handling refrigerant.

1. Take special care to ensure that clearance between air conditioning components and other components such as

brake parts, fuel system and electric wires as specified in this manual.

2. If a problem is found with the air conditioning system due to installation, refer back to the manual to correct the

problem(s).

3. Vehicle and air conditioning kit components as well as installation procedures are subject to change without prior

notice. Refer to the latest installation manual and service information. Any changes affecting the above items will

be given in the form of a “Installation instructions for air conditioning (Supplement)” (issued by DENSO) or a

service bulletin (issued by the manufacturer).

DEFINITION OF TERMS

! W ARNING : Describes precautions that should be observed in order to prevent injury or death to the user during

installation.

! CAUTION : Describes precautions that should be observed in order to prevent damage to the vehicle or its

components, which may occur during installation if insufficient care is taken.

NOTE : Provides additional information that facilitates installation work.

FRONT, REAR : Shows the direction when viewed from the driver’s seat.

LEFT, RIGHT

DENSO INTERNATIONAL AUSTRALIA PTY LTD

A.C.N. 081 951 402

255 Melrose Drive

TULLAMARINE VIC 3043

First Issue: September , 2001

Publication No: MAC-A552/MAC-A553

Printed in Australia

FOREWORD

This manual has been published to explain how to install the air conditioning for HOLDEN JACKAROO UBS. When

installing the air conditioning, installation should be performed as described in this manual.

[VEHICLE APPLICATION]

VEHICLE NAME MODEL CODE PRODUCTION PERIOD STEERING POSITION DESTINATION

JACKAROO UBS 2001 PETROL 3.5L AUSTRALIA

DIESEL 3.0L

1. GENERAL INFORMATION

1-1 PRECAUTIONS DURING INSTALLATION

1-2 INSTALLATION PREPARATION

1-3 TIGHTENING TORQUE

1-4 PRECAUTIONS FOR SAFETY INSTALLATION

1-5 PIPE JOINT PRECAUTIONS

1-6 GENERAL PRECAUTIONS IN ASSEMBLY

1-7 CHARGING REFRIGERANT (HFC-134a)

2. INSTALLATION INSIDE PASSENGER COMPARTMENT

3. INSTALLATION INSIDE ENGINE COMPARTMENT

4. AFTER INSTALLATION

4-1 CHARGING REFRIGERANT (HFC-134a)

4-2 FINAL LEAKAGE CHECK

4-3 RE-ADJUSTMENT OF COMPRESSOR BELT

4-4 FINAL INSPECTION (SAFETY CHECK)

4-5 RESTORE THE VEHICLE

4-6 FINAL INSPECTION (SAFETY CHECK)

MAC-A552/MAC-A553

DENSO INTERNA TIONAL AUSTRALIA PTY L TD

BOLT LENGTH RULER (mm)

BOLT DIAM. & HEX. HEAD (mm)

(mm)

20 1030405060708090

M14M12M10M8M6M5

– 1 –

1. GENERAL INFORMATION

1-1 PRECAUTIONS DURING INSTALLATION

1. The contents given in “WARNING” and “CAUTION “ in this manual must be adhered to during installation. If they

are ignored, not only the functions of the air conditioning are hindered, but also personal injury or damage to the

vehicle may result. Always carry out the installation in accordance with the “WARNING” and “CAUTION” as noted.

2. Safety Precautions

(a) If installation is carried out by more than two persons, always pay attention to co-worker’s safety.

(b) When the engine is running, make sure that sufficient ventilation is provided.

(d) When raising the vehicle, refer to the appropriate manufacturer’s service manual.

(e) For heavy duty trucks, when tilting the cabin forward, refer to the service manual provided by the vehicle’s

manufacturer to prevent damage or personal injury. Make sure the cabin is locked down after it has been tilted

forward to prevent it from closing.

1-2 INSTALLATION PREPARATION

(1) Prior to installing the air conditioning, check the following for damage or malfunctions.

(a) Internal and external trim and bodywork.

(b) Engine idle speed.

(d) All vehicle functions. (Headlights, indicators, horn, etc.)

(2) Air Conditioning parts preparation

(a) Make sure that the correct kit has been selected for the installation.

(b) When unpacking the kit, lay out all parts in order of installation and check for missing or damaged parts.

[INSTALLATION TOOLS]

WARNING

– 2 –

[Unit : kgf·cm]

1-3 TIGHTENING TORQUE

(1) Where tightening torque is specified, always tighten there with the specified torque.

(2) Where tightening torque is not specified, refer to the tightening torque table.

(3) Bolts marked with i must be used for engine components, which are likely to be subject to heavy load. Never

substitute the bolts marked i with other bolts.

(4) Nuts must be fastened with the tightening torque specified for the related bolts.

[TIGHTENING TORQUE TABLE (GENERAL)]

6 1.00 4.0± 0.7 4.7± 0.7 5.8± 1.0 7.9± 1.3

8 1.25 9.4± 1.8 11.5± 2.1 14.1± 2.4 18.7± 3.6 21.7± 4.3 28.1± 5.4

10 1.25 18.8± 3.6 23.8± 4.6 29.0± 5.7 38.2± 7.4 44.8± 8.6 56.7±11.4

12 1.25 37.4± 6.8 43.2± 8.5 52.8±10.4 69.9±13.6 79.6±15.7 104.5±20.7

14 1.50 54.7±10.8 67.0±13.2 79.3±15.8 108.1±21.6

16 1.50 82.9±16.5 100.9±20.2 126.0±25.2 165.7±33.1

6 1.00 55± 10 65± 10 80± 15 110± 20

8 1.25 130± 25 160± 30 195± 35 260± 50 300± 60 390± 75

10 1.25 260± 50 330± 65 400± 80 530± 105 620± 120 800±160

12 1.25 480± 95 600± 120 730± 145 970± 190 1100± 220 1450± 290

14 1.50 760± 150 930± 185 1100± 220 1500± 300

16 1.50 1150± 230 1400± 280 1750± 350 2300± 460

6 1.00 5.4± 1.0 6.4± 1.1 7.8± 1.4 10.8± 1.9

8 1.25 12.7± 2.5 15.7± 2.9 19.1± 3.4 25.5± 5.9 29.4± 5.9 38.2± 7.4

10 1.25 25.5± 4.9 32.4± 6.3 39.2± 7.8 52.0±10.2 60.8±11.8 78.5±15.6

12 1.25 47.1± 9.3 58.8±11.7 71.6±14.2 95.1±18.6 107.9±21.5 142.2±28.3

14 1.50 74.5±14.7 91.2±18.1 107.9±21.6 147.1±29.4

16 1.50 112.8±22.5 137.3±27.5 171.6±34.3 225.6±45.1

Diam.

(mm) Pitch

(mm)

[Unit : N·m]

4T 5T 6T 7T 8T 10T

Diam.

(mm) Pitch

(mm) 4T 5T 6T 7T 8T 10T

Diam.

(mm) Pitch

(mm)

[Unit : ft·lbf]

4T 5T 6T 7T 8T 10T

[IDENTIFICATION OF BOLT STRENGTH (BOLT SIZES)]

– 3 –

[TIGHTENING TORQUE TABLE (FOR PIPES)]

STRUCTURE

<COOLING UNIT>(EXCEPT ONE BOLT PLATE TYPE)

TIGHTENING TORQUE

N·m

BOLT & NUT

SIZE

1/4"

1/2"

5/8" OR 6/8"

TUBE SIZE

7.8±1.0 80±10 5.8±0.7

13.7±1.0 140±10 9.8±1.0

22.5±2.0 230±20 16.2±1.7

32.3±2.0 330±20 23.4±1.7

9.8±2.0 100±20 7.2±1.3

kgf·cm ft·lbf

5.4±1.0 55±10 4.0±0.7

(ONE BOLT PLATE TYPE)

O-RING

BOLT

TUBE

COOLING

UNIT

PUSH

PLATE

– 4 –

(5) Take care not to scratch any part of the vehicle.

Bind the tips of tools (clip remover, slot screwdriver etc.)

with a piece of vinyl tape to prevent damage to parts of the

vehicle.

1-4 PRECAUTIONS FOR SAFETY INSTALLATION

(1) Do not proceed with the installation until the battery cables

have been disconnected or a short-circuit may result.

NOTE

1. Always disconnect the NEGATIVE CABLES first.

2. When RECONNECTING the cables, make sure to

connect the positive cable to the positive battery terminal

and the negative cable to the negative battery terminal.

(4) The bolts,nuts and fittings where specified must be torqued

to proper specification. If torque is not specified, refer to

TIGHTENING TORQUE TABLE on page 3.

(3) Use protective covers to avoid damage to the vehicle and

the air conditioning parts.

• Seat covers

• Fender covers

• Floor covers

(2) Do not smoke or expose open flame near the vehicle during

installation.

NOTE

Pay special attention when working on the fuel system.

– 5 –

(6) When installing the A/C harnesses, route properly avoiding

interference with surrounding parts.

(7) Do not pull on vehicle wires and/or wire harnesses. To

uncouple electrical connectors, pull only on the connector

itself to avoid damage.

NOTE

In case of lock type connectors, make sure that the

connectors are unlocked before disconnecting.

When re-connecting the connectors, insert them until a

clicking noise is heard. After they are connected, hold

and pull them gently to check that they are connected

properly.

(8) Before making any hose and tube connections, apply a

few drops of compressor oil to the seat of O-ring to avoid

refrigerant leakage.

(9) When removing an O-ring from a tube, use a wooden or

nylon awl to prevent damaging the tube.

NOTE

Always replace the existing O-rings with new ones

specified for refrigerant HFC-134a.

(10)When tightening or loosening fittings, use two wrenches

to prevent the tubes from twisting. After loosening the

fittings, tighten them with specified torque.

– 6 –

(11) Do not remove protective caps from fittings until each

component is ready for connection.

NOTE

If the receiver is left uncapped for a long time, the desiccant

inside the receiver may absorb moisture, causing damage

to the air conditioning.

(13)Always keep the refrigerant container (service drum) below

40°C (104 °F).

NOTE

Do not store the refrigerant container in an area where it

can be exposed to direct sunlight, near a source of fire, or

an area such as the inside of a car (the trunk etc.), where

the temperature may become high. Store the container in

a dark place with low-humidity.

(12)When handling refrigerant, always wear proper eye

protection and do not allow it to come in contact with skin.

(14)Do not expose refrigerant to an open flame.

(15)Do not drop compressor oil (ND-OIL 8, 9) onto the vehicle

surface. It causes the discoloration of the vehicle’s body

surface, or deterioration of the acrylic or ABS plastic

components.

– 7 –

(16)Use the refrigerant HFC-134a (R134a).

NOTE

The very different characteristics of refrigerants HFC-134a

(R134a) and CFC-12 (R12) have determined the design

of their respective air conditioning systems. Under no

circumstances allow CFC-12 (R12) to enter an HFC-134a

(R134a) system, or vice versa, because serious damage

could occur.

(19)When recovering refrigerant, use the necessary special

service tools.

NOTE

1. Support the service valve by hand to prevent the tube

from bending when connecting the charging hose.

2. Using a general tool like a screwdriver may cause

refrigerant leak by damaging the service valves.

(17)Use the correct compressor oil.

NOTE

Compressor oil used in pre 1993 vehicles CFC-12 (R12)

air conditioning systems cannot be used in HFC-134a

(R134a) air conditioning systems.

For a swash plate type compressor : 200PG (ND-OIL 8)

For a vane type compressor: 100PG (ND-OIL 9)

(18)Use HFC-134a (R134a) gas leak detector.

NOTE

The CFC-12 (R12) leak detector is not sensitive enough

to detect HFC-134a (R134a).

– 8 –

(20)Use manifold gauges for HFC-134a (R134a).

NOTE

1. Manifold gauges

Always use HFC-134a (R134a) dedicated manifold

gauges to prevent CFC-12 (R12) and CFC-12 (R12)

compressor oil contaminating the HFC-134a (R134a)

system.

2. Vacuum pump adapter

(1) By connecting a vacuum pump adapter, the vacuum

pump can be used for both HFC-134a (R134a) and

CFC-12 (R12) air conditioning systems.

(2) Be sure to turn off the manifold gauge valve

immediately after evacuating the system, then switch

off the vacuum pump. If this order is reversed, the

line will be temporarily open to atmosphere.

(21)After installing the drive belt, check the belt tension using

a belt tension gauge DENSO BTG-20 or BORROUGHS

BT-33-73F.

NOTE

1. The belt tension must be measured between the

specified pulleys as indicated in the installation manual.

2. A “New belt” refers to a belt which has been used for

less than 5 minutes of operation.

A “Used belt” refers to a belt which has been used for

more than 5 minutes of operation.

3. The drive belt requires accurate tension adjustment ; a

slack belt is likely to cause the belt to whine, while

excessive tension may result in damage to the bearings

or the idle pulley bracket.

4. After installing the drive belt, make sure it is properly

seated in the grooves of the pulley.

– 9 –

1-5 PIPE JOINT PRECAUTIONS

(1) Common to all pipe joints

(a) When connecting pipes, after complete mating (pre-mating)(see the illustration below) tighten bolts or nuts.

Reason : Installation without complete mating often causes slanted installation, pinched O-rings, or scratches on

seal surfaces.

(d) Check that no dust is on the O-ring mating parts.

Also do not touch O-rings with gloves on.

(b) Always apply the specified compressor oil (*) to an O-ring before installing it. However , when resin (such as acrylic

resin or ABS plastic) is in the area, beware of the possibility that oil causes environment al stress cracking to these

resins. Be careful to prevent foreign materials from contaminating the oil.

(*) 10P-type, 7SB, scroll : ND8 T V-type : ND9

Determination

OK NG NG

Block joint

OK NG NG

Nut union

Complete Mating

(Insert a male part into a female part.)

Incomplete Mating

Determination

l: Incomplete joint (an opening)

– 10 –

(e) Do not add excessive force to pipes. Do not deform pipes.

(f) Arrange hoses well. For example, it is not allowed to

bend or twist engine mounted hoses.

Reason : Resin inside of hoses may be bent or scratched,

and it may lower the permeation-proof function.

1-6 GENERAL PRECAUTIONS IN ASSEMBLY

(1) Be careful to keep parts, service tools, mating parts of various service equipment (including O-rings) free from

unspecified oil or dust.

(2) Avoid using refrigerant oil (such as ND-8 or ND-9) near painted surfaces and resin materials (acrylic resin, ABS

plastic, or polycarbonate).

(3) Remove a receiver shipping cap only just before mounting (connecting pipes). Also mount a receiver last of all the A/

C system parts, or at least assemble system parts while the receiver shipping cap is removed for only a short time (for

1 hour or less).

(2) Nut union-type

(a) Always assemble pipes using 2 wrenches.

(b) Pipes will rotate from 15° to 20° clockwise during

tightening, so anticipate the displacement caused by

rotation of the nut and then mount pipes.

(the female side).

(g) Remove a shipping cap just before connecting pipes.

Reason : To keep O-rings or O-ring seals from dust.

(h) During air conditioning installation, confirm there is no

interference between the pipes and vehicle parts. (Keep

proper clearances.)

– 11 –

1-7 CHARGING REFRIGERANT (HFC-134a)

(1) Connect the quick disconnect adapters to charging hoses.

(2) Remove the caps from the service valves on the refrigerant

line.

(3) Install the manifold gauge set to the service valves.

(a) Close both high and low pressure valves of manifold

gauge set.

(b) Connect the quick disconnect adapters to the service

valves.

(4) Evacuate air in refrigeration system.

(a) Connect the vacuum pump adapter to the vacuum pump.

(b) Connect the center hose of the manifold gauge set to

the vacuum pump adapter.

on the vacuum pump.

(d) After ten minutes or more, check that the low pressure

gauge indicates -0.1 Mpa ( -750 mm Hg ) or less.

NOTE

If the reading is not -0.1 Mpa ( -750 mm Hg ) or less,

close both valves of manifold gauge set and stop vacuum

pump.

Check the system for leaks and repair as necessary.

(e) Close both valves and turn off the vacuum pump.

(f) Leave the system in this condition for five minutes or

longer and check that there is no change in the gauge

indicator.

CAUTION

When connecting charging hose to A/C charging valve,

do not use excessive force. Excessive force may damage

charging valves and deform pipes.

– 12 –

(5) Install charging cylinder.

(a) Charge the proper amount of refrigerant into the charging

cylinder.

(b) Connect the center hose to the charging cylinder.

CAUTION

Do not open both high and low pressure valves of manifold

gauge set at this time.

(d) Press the valve core on the side of manifold gauge and

expel the air inside of the center hose.

(6) Inspect the refrigeration cycle for leaks.

(a) Open the high pressure valve and charge refrigerant.

(b) When the low pressure gauge indicates 98 kPa

(1kgf/ cm2, 14 psi), close the high pressure valve.

(d) If leak is found, repair the faulty component or connection.

And evacuate the air in refrigeration cycle.

CAUTION

Use refrigerant recovery/recycling machine to recover the

refrigerant whenever replacing parts.

– 13 –

CAUTION

1. After charging refrigerant, be sure to tighten the charg-

ing valve cap.

Recommended tightening torque specification: 0.25

N·m or more

2. If a valve cap is removed, dust or moisture can enter,

and the seal portion on the valve is corroded. This

deteriorates sealing performance, leading to a possible

refrigerant leak.

(7) Charge refrigerant into the refrigeration cycle.

CAUTION

1. Never run the engine when charging the system through

the high pressure side.

2. Do not open the low pressure valve when the cycle is

being charged with liquid refrigerant.

(a) Open the high pressure valve fully.

(b) Charge the specified amount of refrigerant, then close

the high pressure valve.

NOTE

A fully charged system is indicated by the sight glass being

free of any bubbles.

(8) Remove manifold gauge set from service valves.

(a) Close both valves of manifold gauge set.

(b) Disconnect quick disconnect adapters from service

valves.

(9) Install the caps to service valves on the refrigerant line.

-14-

(e) Glove box surround.

NOTE:

Disconnect glove box light.

1. REMOVAL OF PARTS

(a) Glove box.

(b) Gearshift and transfer case knobs (FOR M/T VEHICLES ONLY).

(d) Centre surround.

GLOVE BOX

CENTRE

SURROUND

KNOBS

CENTRE CONSOLE

GLOVE BOX

SURROUND

2. INSTALLATION INSIDE PASSENGER COMPARTMENT

1. Be sure to use the correct oil, refrigerant and charging/recovery equipment.

2. Before starting installation, read all “PRECAUTIONS FOR SAFETY INSTALLATION” thoroughly and follow the

instructions described in it.

3. Before starting installation, remove the (–) terminal of the battery and ensure seat/floor covers are in position.

4. Take care not to scratch any parts of the vehicle.

5. Sort removed bolts and tapping screws into groups so that they can be reassembled correctly.

CAUTION

-15-

(g) Air duct.

(f) Dash panel support.

(h) Blower resistor and backing plate (reuse).

(i) Air duct (discard).

NOTE:

Blower resistor mounting screws to be reused.

NOTE:

Disconnect blower resistor wire harness.

DASH PANEL

SUPPORT

AIR DUCT

(DISCARD)

BACKING PLATE (REUSE) BLOWER

RESISTOR

(REUSE)

SCREW

(REUSE)

-16-

(j) Fire wall grommets and insulation pads.

(k) Original nut (reuse).

2. COOLING UNIT

(a) Assemble blower resistor (reuse) to the

cooling unit using two original screws and

backing plate (reuse).

NOTE:

Make sure orientation of blower resistor is as

shown.

(b) Attach packing to drain hose extension.

unit.

INSULATION

PADS

GROMMETS

ORIGINAL NUT

(REUSE)

DRAIN HOSE

EXTENSION

PACKING

COOLING UNIT

BACKING PLATE

(REUSE)

BLOWER

RESISTOR

SCREWS (REUSE)

UPWARD

BLOWER

RESISTOR

-17-

CAUTION:

Ensure drain hose extension is flush with

firewall.

(d) Connect vehicle harness to blower resistor.

(e) Install cooling unit using two washer faced nuts, gold coloured and one original nut (reuse).

(f) Connect A/C harness to vehicle harness (3P) and cooling unit thermostat (5P).

NOTE:

Must install blower resistor vehicle harness prior to installing cooling unit.

COOLING UNIT

THERMOSTAT

NUT

(M6)

(NEW)

NUT (M6)

A/C HARNESS

NUT (M6)

(NEW)

VEHICLE HARNESS

BLOWER RESISTOR

(REUSE)

DRAIN HOSE

EXTENSION

FIREWALL

-18-

3. A/C SWITCH

(a) Remove A/C switch blanking plate.

(b) Install A/C switch.

4. REINSTALLATION

(a) Attach packing around wire harness

connector as shown.

(b) Reinstall dash panel support bar.

DASH PANEL

SUPPORT

VEHICLE

AND A/C

HARNESS

PACKING

A/C A/C SWITCH

PLATE

(g) Install drain hose to drain hose extension from

inside engine compartment.

CAUTION:

Ensure drain hose is routed between chasis

rail and body panel and pointing downward and

toward the rear.

-19-

(b) Hood lock.

NOTE:

Mark out position of hood lock with a pencil

before removal.

• FOR DIESEL E/G VEHICLES ONLY D) - F)

(d) Air inlet assembly.

(e) Radiator overflow bottle.

GRILLE

RADIATOR OVERFLOW

BOTTLE

AIR INLET ASSEMBLY

3. INSTALLATION INSIDE ENGINE COMPARTMENT

1. TEMPORARY REMOVAL

(a) Grille.

-20-

(f) Remove air duct.

( g) Remove bolt from cold start switch (discard bolt).

(h) Cover intercooler with cardboard to preventdamage.

(i) Remove second battery.

(j) Remove and discard original ambient sensor bracket.

•FOR PETROL E/G VEHICLES ONLY G) - H)

(g) Air cleaners assembly.

AIR CLEANER ASSY

-21-

(b) Install condenser using two bolts.

NOTE:

Make sure condenser bushes are located

into cross beam slots.

CAUTION:

Keep clearance more than 20mm

between condenser and horn.

Reposition horn away from condenser if

necessary.

2. CONDENSER

(a) Install bushes onto condenser.

NOTE:

Install onto bottom rear legs of condenser

bracket.

3. RECEIVER DRIER

(a) Loosely assemble bracket onto receiver drier.

BUSH BUSH

BOLT

(M6 X l30)

BOLT

(M6 X l30)

HORN

-22-

(b) Install receiver drier assembly onto

condenser using two bolts.

CONDENSER

BOLT (M6 X l12)

RECEIVER DRIER ASSY

-23-

CLAMP

RECEIVER DRIER

CONDENSER

LIQUID TUBE ①

DISCHARGE

HOSE

LIQUID

TUBE ➂

SUCTION

HOSE

LIQUID TUBE ➁

•DIESEL

•PETROL

-24-

1. DISCHARGE HOSE

(a) Install bush A onto upper radiator support panel.

NOTE:

Use existing weld nut on panel.

•FOR PETROL E/G VEHICLES ONLY (b) - (d)

(b) Install bush B using a nut onto radiator support

panel.

(d) Install bracket to bush B using a nut.

BUSH A

BUSH B

CLAMP

BRACKET

NUT (M6)

BRACKET

NUT

(M6)

CLAMP

PANEL

NUT

(M6)

(e) Install discharge hose to compressor and

condenser.

Tightening torque: 10 N.m

( f) Fasten discharge hose using plastic clamp.

-25-

• FOR DIESEL E/G VEHICLES ONLY

(j) Remove compressor cap (do not discard bolt).

(k) Place suction hose to compressor.

(l) Place discharge hose to compressor over the

suction hose fitting.

(m) Fasten both hoses to the compressor using

original bolt.

Tightening torque: 39 N.m

2. SUCTION HOSE

• FOR PETROL E/G VEHICLES ONLY

(a) Install suction hose to compressor and cooling unit.

CAUTION:

Make sure suction hose passes over

vehicle wire harness.

Tightening torque: 10 N.m

SUCTION

HOSE

VEHICLE

WIRE

HARNES

COMPRESSOR

BOLT

(M6 X l35)

CAUTION

(n) Install plastic clamp to the bracket.

(o) Install bracket on top of hood support pole bracket.

CAUTION:

Make sure hood is supported.

(p) Install discharge hose to condenser.

Tightening torque: 10 N.m

CAUTION:

Ensure distance between battery and

discharge hose is minimum 10mm.

(q) Remove two cable ties from harnesses.

(r) Reposition harness below clamp.

(s ) Install two new cable ties to maint ain 10mm

clearance between hose and harness.

▲▲

▲

HOSE

▲▲

▲

▲▲

▲

▲▲

▲

▲▲

▲

CLAMP

CABLE TIE

HARNESS

-26-

3. LIQUID TUBE

•FOR PETROL E/G VEHICLES ONLY

(a) Install liquid tube 1 to receiver drier and

condenser.

Tightening torque:

Receiver: 5 N.m

Condenser: 10 N.m

(b) Fully tighten receiver drier bracket.

RECEIVER DRIER

CONDENSER

LIQUID TUBE ①

BOLT

(M6 X l25)

BOLT

(M6 X l45)

( f ) Install clamp on heater hose and vacuum hose to

maintain clearance from A/C suction tube.

( g) Rotate hose clamp on intercooler to avoid suction

tube.

•FOR DIESEL E/G VEHICLES ONLY

( b) Install two bushes to firewall.

connect to the cooling unit.

Tightening torque:

33 N.m

( d) Fasten the suction tube using two clamps.

( e ) Connect and fully tighten the suction tube to the

suction hose.

Tightening torque:

33 N.m

-27-

•FOR DIESEL E/G VEHICLES ONLY C) - D)

condenser.

Tightening torque:

Receiver: 5 N.m

Condenser: 10 N.m

(d) Fully tighten receiver drier bracket.

RECEIVER DRIER

LIQUID

TUBE ➀

BOLT (M6 X l40)

BOLT (M6 X l25)

( e ) Loosen the bolts holding the second battery tray.

(f ) Install liquid tube 3 to the cooling unit using two plastic clamps and one steel clamp.

NOTE:

Ensure the liquid tube and clamp are mounted between the vehicle body and the battery tray.

-28-

( j) Install liquid tube 2 to liquid tube 3 and

receiver drier.

Tightening torque: 13 N.m

(k) Connect vehicle harness to pressure switch.

NOTE:

Pass harness through radiator support panel

from inside engine compartment.

RECEIVER DRIER

VEHICLE HARNESS

PRESSURE SWITCH

LIQUID TUBE ➁

BOLT (M6 X l25)

•FOR PETROL VEHICLES (g) - (h)

( g ) Install liquid tube 3 to cooling unit.

Tightening torque: 13 N.m

( h ) Fasten liquid tube 3 using two clamps.

( i) Fasten liquid tube 2 using a clamp.

CLAMP LIQUID TUBE ➂CLAMP

NUT (M6)

BOLT

(M6 X l12)

RADIATOR UPPER

SUPPORT PANEL

BUSH

NUT (M6)

CLAMP

WELD

NUT

LIQUID

TUBE ➁

(l) Install ambient sensor to the new bracket supplied.

( m) Ensure harness is clipped on.

( n ) Reuse the nut and the supplied bolt mount on the

bracket to radiator support as shown.

-29-

5. A/C SYSTEM LABEL

(a) Install A/C system label as shown.

( b ) Install ambient sensor to the new bracket supplied.

(c ) Ensure harness is clipped on.

( d ) Reuse the nut and the supplied bolt mount on the

bracket to radiator support as shown.

A/C SYSTEM LABEL

– 30 –

4. AFTER INSTALLATION

4-1 CHARGING REFRIGERANT (HFC-134a)

(1) Automatic charging machine

Before evacuating air or charging refrigerant using the automatic charging machine, read the relevant manuals

thoroughly.

(2) Charging cylinder

When charging refrigerant using a charging cylinder, evacuate air then charge refrigerant as described below.

Charge gaseous refrigerant from Hi

pressure side until the Low pressure

gauge indicates 0.098Mpa (1kgf/cm2).

START EVACUATION

STOP EVACUATION

Leave the system with this

conditioning for 5 minutes.

CHECK FOR AIR LEAKAGE

CHARGE REFRIGERANT

CHECK FOR GAS LEAKAGE

CHARGE REFRIGERANT

CHECK AND CORRECT

EACH CONNECTION

The gauge indicates

abnormal level.

Evacuating time: 10 minutes

Evacuating pressure: 270 pa or less

(–750mmHg)

CAUTION

Ensure to fill the refrigerant to the specified amount.

STANDARD AMOUNT OF REFRIGERANT 650 + 50g

– 31 –

4-2 FINAL LEAKAGE CHECK

This description is provided here as a reference for the checking procedure. When the air conditioner is installed it is

important to fill the specified amount of refrigerant. When checking the refrigerant amount during repairs, for example,

consult the vehicle repair manual.

(1) Check refrigerant amount through the sight glass.

(a) Set the following conditions

Engine speed...Idling

In case of dual type A/C...Switch both front and rear ON.

(b) Visually check a sight glass under the following

conditions.

Appropriate...Almost no bubbles

(Idling speed : After gradually increasing

speed, bubbles disappear at 1500 rpm.)

Excessive...No bubbles

(Pressures on both the high and low side

are high.)

Insufficient...Continuous bubble occurrence

NOTE

1. Pressure on the high pressure side when charging refrigerant should be 19 kg/cm (1.87 Mpa) or less. When

outside air temperature is high (40 °C or more) and if the pressure becomes more than 19 kg/cm (1.87 Mpa),

perform the check in a cool place with all the doors open and with the blower speed set to LO.

2. When an electric fan starts with an appropriate refrigerant level, bubbles might appear temporarily. (For about 5

seconds)

(2) In case of a 'low charge' above, there may be a leak. Then, check joint areas of each part with a leak tester , and repair

the leak.

– 32 –

4-3 RE-ADJUSTMENT OF COMPRESSOR BELT

+0.5

–0 +5

–0

Refer to the vehicle's manual for correct belt tension. Keep in mind that initially after five minutes of A/C operation, the belt

is likely to elongate.

Retension the belt if necessary after A/C operation and check.

4-5 RESTORE THE VEHICLE

Reinstall all the parts of vehicle that have between temporarily removed.

!CAUTION

1. In particular, improper installation of instrument panel’s parts, improper tightening of tapping screws or loose

connectors may cause abnormal noise. Therefore make sure that they are installed or fastened properly to avoid

abnormal noise that can occur after the air conditioning installation is complete.

Tightening torque for tapping screw ....................... 1.5 N·m (15 kgf·cm)

Tightening torque for cross recessed head bolt ..... 3.4 ± 1.4 N·m (35 ± 15 kgf·cm)

2. If the hole for a tapping screws is too large, use a tapping screw one-size larger.

3. Reinstall each part with particular care so that its clips, guides bosses fit in the specified positions.

4. When installing the instrument panel, make sure that wire harness is not pulled, pushed excessively or trapped.

4-4 ADJUSTMENT OF ENGINE IDLING SPEED

!CAUTION

The engine revolution is controlled by a computer, therefore adjustment is not required. (When the air conditioning

system is started, check whether idling revolution increases.

– 33 –

No.

ITEM

Activation of Magnetic Clutch

Blower Motor Speed Change

Air Outlet Change

FRS/REC. Change

Temperature Adjustment

Condenser fan

DESCRIPTION

ON/OFF

Lo to Hi

Lever Operation

COOL to HOT

Operation

4-6 FINAL INSPECTION (SAFETY CHECK)

After installing the air conditioning, check for safety and operation of each section shown below.

(1) Inspection after completion of installation

DESCRIPTION

Install and fasten properly.

Do not pinch harness. Make sure connectors are secure.

Do not bend excessively, pinch or constrict.

Maintain specified or in excess of that specified in the installation manual.

There should be no abnormal noise during operation.

CHECK

(2) Check for operation of the air conditioning unit

ITEM

A/C Parts

Wiring

Vacuum Hoses

Safety Gaps

Compressor

No.

CHECK CHECK

CHECK

(3) Check for operation of each electrical component in the vehicle (To be carried out before and after inst allation of the

air conditioning unit)

Horn

Washer

Wipers

Inside lights

Cigarette lighter

Clock

Radio

Blower Motor

Back up lights

ITEM

Turn Signals

Flashers

Head lights

Stop lights

Tail lights

CHECK ITEM

ITEM Before After

AfterBefore Before After

THE AIR CONDITIONER IS NOW READY FOR USE. BE SURE TO EXPLAIN OPERATION TO THE

OWNER.