Page of 16

Advertising

Advertising

INSTALLATION
INSTRUCTIONS
What's New
The A/C kits and instructions for the 2005 Insight are
carryovers from 2004 with no changes. Kit number
80000-S3Y-A02 is for U.S. vehicles, and kit number
80000-S3Y-C02 is for Canada vehicles.
TOOLS AND SUPPLIES REQUIRED
Clip remover
Open-end wrench set
Screwdrivers
Socket wrench set
Torque wrench
Belt tension gauge
Refrigerant oil (R12 mineral oil or R134a PAG oil)
Fender covers, floor mats, and seat covers
HFC-134a refrigerant recovery/recycling/charging
station
Gloves
Eye protection (face shield, safety goggles, etc.)
Electronic leak detector
Use only HFC-134a in this system; do not use
CFC 12 (Freon); do not install parts designed for
use in a CFC system.
Use a charging station. A/C charging stations and
refrigerant recovery/recycling stations minimize the
release of CFCs and HFCs into the atmosphere.
Use them for all A/C charging and service work
according to their manufacturers' instructions.
Do not overcharge. This system requires only the
amount of HFC-134a refrigerant shown below. If
you overcharge the system, the engine and the A/
C could malfunction.
500 to 550 grams
0.50 to 0.55 kilograms
1.1 to 1.2 pounds
17.6 to 19.4 ounces
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
Accessory
AIR CONDITIONER
INSTALLATION
Customer Information: The information in this
installation instruction is intended for use only by
skilled technicians who have the proper tools,
equipment, and training to correctly and safely add
equipment to your vehicle. These procedures
should not be attempted by "do-it-yourselfers."
NOTE:
AII 28737 (0502)
Application
2005 INSIGHT
Make sure you install the correct part. Use the
illustrations on pages 2 and 3 as a guide to check
the parts before you install them.
Don't remove plugs and caps from fittings until
the parts are ready to install. This will keep out
moisture and dirt that could cause wear and
damage.
Before you connect any line or hose, check and
lube its O-ring. Make sure the O-ring is there (on
the fitting), put a few drops of refrigerant oil on the
O-ring, then connect the fitting.
You may use any type of refrigerant oil to lubricate
O-rings and fittings.
If you add or replace refrigerant oil in the system,
use only this PAG oil: Sanden SP-10,
P/N 38897-P13-A01.
Route and secure the lines and hoses properly;
maintain clearance between them and surrounding
parts.
Before you connect each connector, check its
terminals. Make sure they aren't bent or out of
place.
Publications No.
AII 28737
Issue Date
FEB 2005
1 of 16
08B26-S2A-1000-91

Advertising

   Also See for Honda 2005 INSIGHT

   Related Manuals for Honda 2005 INSIGHT

No related manuals

   Summary of Contents for Honda 2005 INSIGHT

  • Page 1

    INSTRUCTIONS FEB 2005 What's New INSTALLATION The A/C kits and instructions for the 2005 Insight are Customer Information: The information in this carryovers from 2004 with no changes. Kit number installation instruction is intended for use only by 80000-S3Y-A02 is for U.S. vehicles, and kit number skilled technicians who have the proper tools, 80000-S3Y-C02 is for Canada vehicles.

  • Page 2

    Power relay (5P) 39794-S10-003 Information label (USA) 80050-SR3-H00 Information label (Canada) 80500-SP0-000 A/C identification label 8005X-S3Y-A02 80200-S3Y-A10 Group B 38000-PHM-004 38942-PHM-004 90022-PHM-000 38920-PHM-003 2 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 3

    80341-S3Y-A03 80381-SM4-A01 95701-06025-08 95701-06025-08 94050-06050 80381-SV7-A01 95701-06012-05 80315-S3Y-A01 95701-06025-08 80115-S3Y-A01 95701-06025-08 91501-S04-003 80331-S3Y-A01 95701-06012-05 80650-S3Y-A01 80100-S3Y-A01 Group D 8005X-S3Y-A02 39794-S0K-A01 80050-SR3-H00 80050-SP0-000 39794-S10-A01 3 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 4

    Remove the three bolts (two 6 mm and one 5 mm), mounting bolt in then remove the glove box frame. step 9. 4 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 5

    Install the end of the compartment side. drain hose through the hole in the frame. 5 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 6

    Remove the lower Loosen the four steering column mounting nuts steering column cover. enough to lower the column about an inch. 6 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 7

    SHORT BLACK self-tapping screw in this location, or you will damage the instrument panel. Peel the backing off the new temperature ring. 7 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 8

    Remove the four 6 mm washer-bolts from the headlight assembly. center upper beam, then remove the beam and set it aside. 8 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 9

    (16 lb-ft), and check the belt tension. Fit this belt tension gauge (07JGG-001010A) onto the belt. Do not use any gauge other than this one. 9 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 10

    ABS evaporator with a 6 x 25 mm flange modulator bracket. bolt (95701-06025-08). Torque the bolt to 10 N . m (7 lb-ft). 10 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 11

    10 N . m (7 lb-ft). Install the suction hose clamp Remove and discard this bolt and (80361-S3Y-A00) over the suction plug from the compressor. line. 11 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 12

    Torque the bolt to 10 N . m (7lb-ft). Tighten this headlight mounting bolt. Reattach this wire harness clip to the Tighten this upper center beam. headlight mounting bolt. 12 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 13

    Reconnect the negative cable to the 12-volt battery. 13 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 14

    These conditions are not covered by warranty policy. 14 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

  • Page 15

    Torque the idler pulley to 22 N . m (7 lb-ft). • 25. Reinstall the splash shield. Torque the mounting bolts to 10 N . m (7 lb-ft). 15 of 16 © 2005 American Honda Motor Co., Inc. - All Rights Reserved. AII 28737 (0502)

  • Page 16: Circuit Diagram

    Circuit Diagram 16 of 16 AII 28737 (0502) © 2005 American Honda Motor Co., Inc. - All Rights Reserved.

Comments to this Manuals

Symbols: 0
Latest comments: