Service Procedure

1. Discharge the air conditioner refrigerant.
NOTE: Do not discharge refrigerant into the atmosphere. Before discharging the refrigerant, reference Technical Bulletins for important CFC refrigerant (R12) discharge guidelines:
^ HA90-003/NTB90-016
^ HA90-006/NTB90-028

FIGURE 1:

2. Remove the right side cowl top and battery from the cowl top grill area [Figure 1]:

FIGURE 2:

3A. On non-turbo models: remove
these air conditioner pipe and engine compartment components [Figure 2]:
^ Engine air intake duct [A]
^ Low-pressure pipe [B]
^ Compressor joint [C]
^ With the vehicle raised, remove the engine undercover, the low pressure pipe [D] and the flexible hose [E].

FIGURE 3:

FIGURE 4:

3B. On turbo models, with the
vehicle raised, remove these air conditioner pipe and engine compartment components [Figures 3 through 6]:
^ Automatic speed control device actuator [3-A] and solenoid valve [3-B].
^ Engine air intake ducts [4-C].

FIGURE 5:

FIGURE 6:

^ Power steering tank retainer bolts (5-D) and HICAS solenoid [5-E).
Drain the oil from the power steering tank.
^ Power steering fluid hose from the tank (5-F]. ^ Compressor joint [6-G].
^ Raise the vehicle on a hoist.
^ Remove the undercover.
^ Remove the Low pressure pipe (6-H] and low pressure flexible hose [6-I]
^ Disconnect the low pressure pipe [6-J] and clamps [6-K].
^ Lower the vehicle and remove the low pressure pipe [6-J).

FIGURE 7:

4. In the passenger compartment, remove the components A through H [Figure 7] from around the dashboard:

FIGURE 8:

5. Remove the air conditioner cooling and blower units, in this sequence [Figure 8]:
^ Remove the cooling unit pipe grommet and cover from the engine compartment side [8-A].
^ Remove the lower blower unit nut [8-B].
^ Loosen the upper blower unit bolt [8-C].
^ Remove the lower cooling nuts [8-D], then the cooling unit.
^ Remove the upper blower unit bolt [8-C], then the blower unit.

FIGURE 9:

6. Replace the blower unit seal, being certain that there are no gaps between the seal and unit [Figures 9].

FIGURE 10:

7. Install silent tape on the cluster lid vents. Be certain the tape completely seals around the vents [Figure 10].
8. Re-install cooling and blower units in reverse order of removal. Be certain to use the replacement kit cooling unit and grommet.
NOTE: Be certain the areas between the heater unit and cooling unit and between the cooling unit and blover unit are tightly sealed.

9. Re-install the dashboard area components in reverse order of removal.

FIGURE 11 - NON-TURBO MODELS:

FIGURE 12 - TURBO MODELS:

10. Re-install air conditioner pipe and engine compartment components in reverse order of removal. Be certain to use new replacement kit low pressure flexible hose and pipe. Torque fasteners as indicated below [Figures 11 {non-turbo models} & 12 {turbo models}].
11. Check power steering fluid and lines as follows:

FIGURE 13:

^ Without SUPER HICAS system - the fluid level should be checked using the "HOT" range
. on the dipstick, at fluid
temperatures of 122-176~F [50-80~C], or using "COLD" range on dipstick at fluid temperatures of 32-86~F [0-30~C] [Figure 13].

CAUTION: Do not overfill

FIGURE 14:

^ With SUPER HICAS system - maintain the fluid level so that the lower float surface is maintained between the "L" and "H" marks on the gauge rod. The fluid level should be checked when the engine is stopped and the fluid is at operating temperature [Figure 14].

CAUTION: Do not overfill

FIGURE 15:

^ Both systems - check lines for improper attachment, leaks, cracks, damage, loose connections chafing and/or deterioration [Figure 15].
12. Re-install cowl top grill and battery in reverse order of removal. If the retaining clip is broken, be certain to use the replacement kit clip.

13. Recharge the air conditioner system with refrigerant as specified below:
^ Non-turbo models: 1.87-2.09 lbs. [0.85-0.95 kg]
^ Turbo models: 1.65-1.87 lbs. [0.75-0.85 kg]

NOTE: Follow the charging procedures contained in the 1990 3002X Service Manual.