A/C Installation Amendments/Tips (TS 2-02 02159)

A/C INSTALLATION AMENDMENTS/TIPS

TECHNICAL SERVICE BULLETIN

A/C INSTALLATION AMENDMENTS AND TIPS

Model: 1989 SIDEKICK

Bulletin No.: TS 2-02 02159

Group: A/C & HEATING

This information should prove helpful during installation of Sidekick air conditioning.

TEMPORARY REMOVAL OF THE GLOVE BOX BRACKET

To remove the glove box bracket, remove the 2 bolts securing the bracket to the body, and the 1 bolt securing the bracket to the dash. It is not necessary to separate the 2 brackets that are bolted together. (See Fig 1 ).

TEMPORARY REMOVAL OF THE BLOWER MOTOR ASSEMBLY

During the removal of the blower motor assembly, be cautious of the blower motor ground wire attached to the right side kick panel. Also identify the position and correct operation of the fresh air control cable. (See Fig 2 ).

INSTALLATION OF THE A/C SWITCH

When removing the blind cap, avoid contact with the heater control panel. The panel surface can be easily scratched or damaged. Also, prior to installing the A/C switch, test the switch for proper detent action.

FITTING THE CARPET AND SILENCER PAD

The silencer pad may be precut. The carpeting will need to be cut during the A/C installation.

INSTALLATION OF THE COOLING UNIT (EVAPORATOR BOX)

Installation of the cooling unit mounting bolts is easiest if a 10mm socket is used.

INSTALLATION OF GROMMETS

Verify that a water proof seal is achieved between the tubes, grommets, and body panel. If necessary, use a small amount of silicone sealer.

If the condenser line caps are removed during grommet installation, be sure to reinstall the caps to prevent moisture entry or contamination.

REINSTALLATION OF GLOVE BOX BRACKET

When reinstalling the glove box bracket, leave all the bolts loose until the bracket is in position. It should be noted that removal or installation of the amplifier requires removal of the glove box bracket.

REINSTALLATION OF THE BLOWER MOTOR ASSEMBLY

During reinstallation of the blower motor assembly, verify that the ground wire is reattached to the kick panel. Verify that all harness and connectors are secured, to prevent broken wires, bad connections, and rattles. Verify the correct operation of all ventilator controls.

REMOVAL OF THE FRONT GRILL AND BUMPER

The fasteners for the front grill and bumper included removable plastic clips. The removal procedure is to use a small blunt object to depress the center pin of the clip.

For reinstallation, push the pin through the clip until the pin protrudes approximately 1/8 inch. Then insert the clip into the hole and depress the pin until it is flush with the face of the clip. (See Fig 3 ).

CRANKSHAFT PULLEY REPLACEMENT

The crankshaft pulley does not need to be replaced if the vehicle is equipped with power steering.

A/C COMPRESSOR INSTALLATION

During installation of the upper compressor bracket; and the compressor, leave all mounting bolts loose to avoid misalignment. After the adjustment bolt is in place and correct alignment is achieved, tighten all bolts to specification.

A/C COMPRESSOR DRIVE BELT ADJUSTMENT

Adjust the belt tension of the A/C compressor by placing a pry bar between the bracket and the front of the compressor body. Do not pry against the service valve body. (See Fig 4 ).

RADIATOR RESERVE TANK HOSE CLAMP

The radiator reserve tank hose clamp must be installed prior to installation of the front bumper.

CONDENSER FAN INSTALLATION

If bolts of the incorrect length are used during the condenser fan installation, the condenser core may be damaged. (See Fig 5 ).

Install the cover sub-assembly, by placing it under and behind the condenser. Then fasten it with the two original (8 x 20mm) bolts. (See Fig 5 ).

FITTING TORQUE

Use a torque wrench at all line fittings to prevent distortion of O-rings due to over-tightening.