AIR CONDITIONER62-11

5. Positionthe lower righthandsectionof the

instrumentpanellowersupportin placeand attach
usingtwo bolts.
Tightenlhe two bolts to 80 lb-in (9 N.m).

8 . lnstallthe evaporator/blower
motorassemblydrain
hose.
9 . Connectthe A"/Cpressureand suctionlinesto the
evaooratorcore.
Installthe lowerrighthandinstrumentpanelcover
andsecurethe trim panelwithfive screws.
Tightenthe five screws to 80 lb-in (9 N.m).
Do not over-tightenscrews.

k 0. ChargetheA/C systemwith refrigerantin

accordancewiththe charginginstructionsin this
section.
11. Installthe battery.
12. Attachthe batteryholddown.
7 . Positionthe glovebox and secureusingtwo
screws. 13. Connectthe positiveand negativebatterycables.
Tightenthe two screws to 80 lb.in (9 N.m). 14. Removewheelchocks.
* Notice
Makesure there are no wires,connectors,or
componentspinched or pressuredbetween the
glove box and the dashpanel.
 62.12 AIR CONDITIONER

7. Loosenthe compressor drivebelttensioner

pulley
nut.
COMPRESSOR 8. Turnthe tensioneradjustingbolt counter-clockwise
to relievetensionon the belt
Removal
9. Removethe drivebelt.
1. Disconnectthe negativebatterycable.
2. Dischargethe air conditioningsystem.Re{erto
Recovety/Evacuating/Charging in this section.
3. Removethe air conditioner linesfromthe
comoressor.
4. Disconnectthe compressor clutchelectrical
conn€ctor.

10. Lowervehicle.
.ll . Remove
the fourcompressormountingboltsand
removethe compressor.

5 . Raisevehicleandsupport.
o. Removethe four engineundercovermountingbolts
and removethe undercover.

KAr6i!6241-S
 AIR CONDITIONER62.13

Installation
1. Installthe compressorusingfourbolts.
Tightencompressor mounling bolts to 18 lb-ft
(24N.m).
2- Raiseand supportthe vehicle.
3. lnstallthe drivebelt.
4. Ad,ustthe air conditionerdrivebeltto specification.
Specification:0.35 in (9.0 mm) at 22 lb (98 N) of
pressure
5. Tightenthe compressordrivebelttensionerpulley
nut.
Tightenthe tensioner pulley nut to 24 ltsft
(32 N.m).

10. Evacuateand chargethe air conditioner

system.
11. Connectthe negativebatterycable.
12. Startengineand runA,/Csystem.Checkfor leaks
at comoressor.

Installlhe engineundercoverusingfour bolts.

Tightenthe four undercoverbolts to 71 lb-in
(8 N.m).

o g
b @,

CONDENSER
FAN
Removal
.l. Chockwheels.
2. Disconnectnegativebatterycable.
3. Removethe threeclipsattachingthe trim panelto
the uppershroudpanel.
4. Removethe screwretainingthe radiatorgrilleto
the hoodstay.
Caretullydepressthe lour tabson the radiatorgrille
and removethe grillefromthe vehicle.
7. LowertheVehicle. Removethe radiatorgrilleclipsfromthe side
8. Installthe air conditionerlinesto the compressor. shroudDanelsand attachthemto the orille.
Tighienthe air conditionercompressorline
fittings to 18 lb-ft (24 N.m).
9. Connectthe comoressorclutchelectricalconnector.
62-14 AIR CONDITIONER

lnspection
1. Connectan ohmmeterto the condenserfanwire
harnessterminalsand checkfor continuitv. lf there l. -'
is no continuity,
replacethe tan motor.
2. Connecta 12VDCsource(battery)to thefan
molorterminals.It the tan does not turn,reolace
the fan motor.
Installation
1- Positionthe condenserfan in frontof the radiator.
2. Installthe threemountingbolts.
Tighten bolts to 80 lb-in (9 N.m).

KlA163{?{9:S

7. Disconnectthe condenserfan assemblvelectrical

conneclor.

Connectthe condenserfan assemblvelectrical

connector.
Carefullysnapthe radiatorgrilleinto placein front
of the radiatorandcondenser,then secureusino
the previouslyremovedscrews.
KrAt53a2{7S

Removethe threecondenserfan boltsand remove

the condenserfan assembly.

KtA16L2{9.s

Connectthe negativebatterycable.
o. Removewheelchocks.
 AIR CONDITIONER62-15

CONDENSER
Removal
1. Chockwheels.
2. Disconnectnegativebatterycable.
3. Dischargethe air conditioningsystem.Referto
Recovery/Evacuating/Charying in this section.
4. Disconnectrefrigeranthosesat the condenser.
5. Removethe threeplasticretainersattachingthe
trimpanelto the uppershroudpanel.
6. Removethe screwretainingthe radiatorgrilleto
the hoodstay.
7. Carefullydepressthe lour tabson the radiatorgrille
and removethe grillefrom the vehicle.
8. Removethe radiatorgrilleretainingclipsfromthe
side shroudpanelsand attachthemlo the radiator
grille.
9. Disconnect the condenserfan connector.
Disconnectthe wire harnessclipsand separatethe
10. Removethe threecondenserfan assemblybolts wireharnessfromthe shroudoanel.
and removethe condenserfan assembly.
lc. Littthe wire hamessout tromunderthe riohtand
1l . Removethe four hood latchmountinobolts. leftshroudpanels.
* Notice
Carefullylay the center sW on the lower shroud
panel to avoid damage to the radiator.

xtat63a252s

1 6 .Placea pieceof cardboardbetweenthe radiator

and the condenser.
12. Installa Snap-On@Hood ProDRodTool#YA4590 '17. Removethe nuts retainingthe condenser.
or equivalent
to supportthe hood. '18.Removethe condenser pulling
1 3 .Removethe uppershroudpaneland hoodsupport by upward;lifting
the radiatorotf the mountingstudsand pullingthe
rod. condenserforwardand oul of the vehicle.
62.16 AIR CONDITIONER
Inspection
1. Visuallycheckthe condenserfor cracksor damage.
2. Repairfin damagewith a radiatorfin tool.
3. Weareye protectionand backflushthe condenser
witha blastof air.
4. Removeany rocksor solidobjectsfrombetween
thecondenser coils.
Installation
1. Gentlyplacethe condenser intopositionon the
mountingstuds,in frontof the radiator.
2. Placethe radiatoron the mountingstuds.
3. Installthecondenser retainingnuts.
Tighrennuts to 80 lb.in (9 N.m).
4. Removethe cardboard.
5. Insertthe wire hamessunderthe rightand left
shroudpanels.
6. Placethe wire harnessin positionand connectthe
wirehamessclips.
7. Insiallthe uppershroudpaneland hoodsupport
rod.
8. Supportthe hoodwiththe hoodsupportrodand
removethe hoodproprodtool.
9. Installthe centerstayand the tour mountingbolts.
Tighten bolls to 80 tb-.in(9 N.m).
10. Installthe condenser fan assemblyandthethree
condenserfan assemblybolts.
Tighten bolts ro 80 tb-in (9 N.m).
11. Connectthe condenser fan connector.
12. Carefullysnapthe radiatorgrilleinto placein front
of the condenserfan assembly.
.13.Installthe
one screwretainingthe radiatorgrilleto
the hood stav.
14. Installthe threeplasticretainersattachingthetrim
panelto the uppershroudpanel.
15. Connec{the retrigerant hosesto the condenser.
Tighten lower refrigeranthose nuts to I0 lb-ft
(13 N.m).
Tighlen uppel retrigeranthose nuts to 16 lb-ft
(22 N.m).
16. Evacuatethe A'lCsystem.Referto
Recovery/Evacuating/Charging in this section.
Performvacuumtest.
17. Chargethe A,/Csystem.Referto
Recovery/Evacuating/Charging in this section.Add
1.0 oz (30 cc) of retrigerantoil iJthe condenserhas
been replacedwilh a newunit. Performa leaktest.
18.Connectthe negativebatterycable.
19.Startengineand runthe A,/Csystem.Checkfor
leaksat the condenser.
DRIVEBELT
Removal
'|. Chockwheels.
2. Removethe tourengineundercovermountingbolts
and the engineundercover.
 AIR CONDITIONER62-17

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3. Loosenlhe tensioner pulleylocknut.

4. Tum the tensioneradjustingboltcounterclockwise EVAPORATORCORE
to loosenthe drivebelt.
5. Removethe drivebelt.
Disassembly
1. Removeblowerunit. Retetlo Blower/EvaDorator
Un,?in lhis section.
2. Disconnect the blowermotorresistorconnector.
3. Removetwo screwsretainingthe blowermotor
resistor.
4. Removethe blowermolorresistor.

Ktai615240-s

lnstallation
1. Installthedrivebelton the pulleys.
2. Tum the tensioneradiustingboltclockwiseto
tightenthe drivebelt.
Specifieddetlection:0.35 in (9.0mm) at 22 lb
(98 N) of pressure 5. Disconnectthe blowermotorconnector.
3. Tlghtenlhe tensioner pulleylocknut. 6. Removethreescrewsat the top ot the blower
molor.
Tighten lock nut to 24 lb-ft (32 N.m).
7. Removethe blowermotorventtubing.
4. Installthe bottomplateand the four mountingbolts.
8. Removethe blowermotorwiththefan wheel
5. Removewheelchocks. aftached.
62.18 AIR CONDITIONER

{ -

t(l416342-t4S

9. Removethe four blowerinletductscrews.

10. Removethe blowerinletduct.
1 6 .Removethe dashsealfromaroundthe evaporator
coretube connections.
1 7 .Detachelevenretainingclipsholdingthe two
halvesof the blowerhousingunit together.

Krar6342-t5S

1 1 .Removethe two wire connectorsto thethermostat.

(BRNwireon the left,BLUMHTwireon the right.)

18. Separatethe two halvesof the blowerhousing

unit,
exposingthe evaporatorand blowermotor.

12. Disconnect
the conneclorto the A,/Crelay.
13. Removetwo screwsand removetheA,/Crelay.
14. Disconnect
the connectorto the A"/Ccut relay.
15. Removetwo screwsand removetheA,/Ccut relav Kta163{2.195
 AIR CONDITIONER62-19

19. Removethe thermostatprobeclipsfromthe

evaporalioncoreand removethe thermostatprobe
from the evaporatorcore.
20. Removethe evaporatorcorefromthe bottom
sectionof the blowerhousinqunit.
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KlA1G3.dl-2{tS
2 1 . Removethe C-clipretainingthe fan wheelon the
blowermotorshaft.
22. Removethe fan wheelfromthe blowermotor.
Assembly
1. Positionthe evaporaiorintothe bottomhalf ol the
blowerhousingunit.
2. Installthe sealaroundthe evaporator.
3. Assemblethe two halvesof the blowerhousingunit
together.
4. Fastenthe two halvesin placewithelevenretaining
clips.

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KlAl63-,64-23.5

Inspection 5. Installthe fan wheelon the blowermotorshaft.

1. Inspectthe blowerhousingunitfor cracks,damage 6. Insertthe C-clipto retainthefanwheelonthe
and waterleakage. blowermotorshaft.
Inspectthe evaporatortor distortedor bentinletor
outlet.
J. Inspectthe fan wheelfor bentfins.
62-20 AIR CONDITIONER
'12.Installthe blowermotorresistor.
13. Inserttwo screwsto holdthe blowermolorresistor
in olace. i.
Tighten the two screws to 62 lb-in (7 N.m).
'14.Attachthe blowermotorresistorconnectorto
the

N\) resistorassemblv

7. Attachthe two wireconnectorslo the thermostat.

(BRNwireon the left,BLUMHT wireon the right.)

rcar63s2-135

15. Positionthe A,/Crelayin place.

16. Inserttwo screwsto holdtheA"/Crelayin place.
Tighten the two screws to 62 lb-in (7 N.m).
17. Attachthe connectorlo the A,/Crelay.
18. Positionthe A,/Ccut relayin place.
KtatG}{2-ta,s
19. Inserttwo screwsto holdthe A,/Ccut relayin place.
Tighten the two screws to 62 lb-in (7 N.m).
8. lnstallthe blowermotorinto the blowerhousino
unit. 20. Attachthe connectorto theA,/Ccut relav.
9. Insertthreescrewsto holdthe blowermotorin
place.
Tightenthe three screws to 62 lb-in (7 N.m).
10. Attachthe connectorto the blowermotor.
'11. Installthe blowermotorventtubino.

21. Installthe dashsealon the evaporatorcoretube

conneclrons.