REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0711008030k5

Replacement Part

L.H.D.

Cooler hose (HI)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Discharge the refrigerant. (See REFRIGERANT RECOVERY.) (See REFRIGERANT CHARGING.)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008808

5.  Disconnect the cooler hose (HI). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

6.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008809

7.  Remove the cooler hose (HI). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

8.  Install in the reverse order of removal. (See Refrigerant line installation note (1).) (See Refrigerant line installation note (2).)

9.  Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Cooler hose (LO)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Discharge the refrigerant. (See REFRIGERANT RECOVERY.) (See REFRIGERANT CHARGING.)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Detach the clip.

ac5wzw00008810

5.  Remove the bolt.

6.  Disconnect the engine ground.

7.  Remove the clip for the vehicle wiring harness connector.

ac5wzw00008811

8.  Remove the bolts.

9.  Set the PCM out of the way.

ac5wzw00008812

10.  Remove the nut.

ac5wzw00008813

11.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008814

12.  Disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

13.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008815

14.  Disconnect the cooler hose (LO). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

15.  Remove the cooler hose (LO). Do not allow compressor oil to spill.

ac5wzw00008816

16.  Install in the reverse order of removal. (See Refrigerant line installation note (1).) (See Refrigerant line installation note (2).)

17.  Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Cooler pipe

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Discharge the refrigerant. (See REFRIGERANT RECOVERY.) (See REFRIGERANT CHARGING.)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Detach the clip.

ac5wzw00008810

5.  Remove the bolt.

6.  Disconnect the engine ground.

7.  Remove the clip for the vehicle wiring harness connector.

ac5wzw00008811

8.  Remove the bolts.

9.  Set the PCM out of the way.

ac5wzw00008812

10.  Remove the nut.

ac5wzw00008817

11.  Remove the clip.

12.  Disconnect the refrigerant pressure sensor connector.

13.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008814

14.  Disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

15.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008818

16.  Disconnect the cooler pipe. Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

17.  Remove the cooler pipe. Do not allow compressor oil to spill.

ac5wzw00008819

18.  Install in the reverse order of removal. (See Refrigerant line installation note (1).) (See Refrigerant line installation note (2).)

19.  Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Refrigerant line removal note

Caution

•  When securing the block with pliers, wrap a clean cloth around the block. If the block is secured with pliers directly, it could be damaged.

1.  Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then tighten the connection bolt or nut.

ac4ccw00002366

Refrigerant line installation note (1)

1.  Apply compressor oil to the O-rings and connect the joints.

2.  Tighten the joint bolt by hand.

Caution

•  When securing the block with pliers, wrap a clean cloth around the block. If the block is secured with pliers directly, it could be damaged.

3.  Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then tighten the connection bolt or nut.

ac4ccw00002366

Refrigerant line installation note (2)

1.  After replacing the refrigerant line, add compressor oil to the refrigeration cycle.

Replaced refrigerant line	Supplemental compressor oil amount (approx. quantity)
Cooler Hose (HI)	1 ml {1 cc, 0.03 US fl oz}
Cooler Hose (LO)	3 ml {3 cc, 0.1 US fl oz}
Cooler Pipe	1 ml {1 cc, 0.03 US fl oz}

R.H.D.

Cooler hose (HI)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Discharge the refrigerant. (See REFRIGERANT RECOVERY.) (See REFRIGERANT CHARGING.)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008808

5.  Disconnect the cooler hose (HI). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

6.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008809

7.  Remove the cooler hose (HI). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

8.  Install in the reverse order of removal. (See Refrigerant line installation note (1).) (See Refrigerant line installation note (2).)

9.  Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Cooler hose (LO)

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Discharge the refrigerant. (See REFRIGERANT RECOVERY.) (See REFRIGERANT CHARGING.)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the nuts.

ac5wzw00008820

5.  Remove the nuts.

ac5wzw00008821

6.  Remove the insulator as shown in the figure.

ac5wzw00008822

7.  Detach the clip.

ac5wzw00008810

8.  Remove the bolt.

9.  Disconnect the engine ground.

10.  Remove the clip for the vehicle wiring harness connector.

ac5wzw00008811

11.  Remove the bolts.

12.  Set the PCM out of the way.

ac5wzw00008812

13.  Remove the nut.

ac5wzw00008823

14.  Remove the cooler hose (LO) from the clip.

15.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008824

16.  Disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

17.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008815

18.  Disconnect the cooler hose (LO). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

19.  Remove the cooler hose (LO). Do not allow compressor oil to spill.

ac5wzw00008825

20.  Install in the reverse order of removal. (See Refrigerant line installation note (1).) (See Refrigerant line installation note (2).)

21.  Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Cooler pipe

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Discharge the refrigerant. (See REFRIGERANT RECOVERY.) (See REFRIGERANT CHARGING.)

3.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the nuts.

ac5wzw00008820

5.  Remove the nuts.

ac5wzw00008821

6.  Remove the insulator as shown in the figure.

ac5wzw00008822

7.  Detach the clip.

ac5wzw00008810

8.  Remove the bolt.

9.  Disconnect the engine ground.

10.  Remove the clip for the vehicle wiring harness connector.

ac5wzw00008811

11.  Remove the bolts.

12.  Set the PCM out of the way.

ac5wzw00008812

13.  Disconnect the refrigerant pressure sensor connector.

ac5wzw00008826

14.  Remove the nut.

ac5wzw00008823

15.  Remove the cooler hose (LO) from the clip.

16.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008824

17.  Disconnect the cooler hose (LO) and cooler pipe. Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

18.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008815

19.  Disconnect the cooler hose (LO). Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

20.  Remove the cooler hose (LO). Do not allow compressor oil to spill.

ac5wzw00008825

21.  Disconnect the vacuum hose.

ac5wzw00008827

22.  Set the heater hose out of the way as shown in the figure.

ac5wzw00008828

23.  Remove the cooler pipe from the clips.

ac5wzw00008829

24.  Remove the bolt. (See Refrigerant line removal note.)

ac5wzw00008818

25.  Disconnect the cooler pipe. Do not allow compressor oil to spill.

Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign matter out of the cycle.

26.  Remove the cooler pipe. Do not allow compressor oil to spill.

ac5wzw00008830

27.  Install in the reverse order of removal. (See Refrigerant line installation note (1).) (See Refrigerant line installation note (2).)

28.  Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Refrigerant line removal note

Caution

•  When securing the block with pliers, wrap a clean cloth around the block. If the block is secured with pliers directly, it could be damaged.

1.  Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then tighten the connection bolt or nut.

ac4ccw00002366

Refrigerant line installation note (1)

1.  Apply compressor oil to the O-rings and connect the joints.

2.  Tighten the joint bolt by hand.

Caution

•  When securing the block with pliers, wrap a clean cloth around the block. If the block is secured with pliers directly, it could be damaged.

3.  Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then tighten the connection bolt or nut.

ac4ccw00002366

Refrigerant line installation note (2)

1.  After replacing the refrigerant line, add compressor oil to the refrigeration cycle.

Replaced refrigerant line	Supplemental compressor oil amount (approx. quantity)
Cooler Hose (HI)	1 ml {1 cc, 0.03 US fl oz}
Cooler Hose (LO)	3 ml {3 cc, 0.1 US fl oz}
Cooler Pipe	1 ml {1 cc, 0.03 US fl oz}