REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Replacement Part

Note

•  The refrigerant line consists of the following parts.

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Front 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 bolt. (See Refrigerant line removal note.)

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5.  Disconnect the front 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.

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

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7.  Remove the front 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.

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.)

Front 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.)

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5.  Disconnect the front 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.)

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7.  Remove the front 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.)

Front cooler pipe (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 following parts:

(1)  Engine cover (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(2)  Battery (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(3)  Battery tray (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(4)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(6)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

(7)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(8)  Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

(9)  Keyless beeper (with advanced keyless entry system) (See KEYLESS BEEPER REMOVAL/INSTALLATION.)

(10)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

4.  Remove the nuts.

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5.  Remove the insulator.

6.  Set the front heater hose No.1 and No.2 out of the way as shown in the figure.

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

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8.  Disconnect the front 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.

9.  Remove the nut.

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10.  Loosen the nut.

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11.  Disconnect the rear 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.

12.  Remove the front cooler pipe (LO) from the clip.

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

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

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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.)

Front cooler pipe (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 following parts:

(1)  Engine cover (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(2)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

(3)  Battery (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(4)  Battery tray (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(6)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

(7)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(8)  Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

(9)  Keyless beeper (with advanced keyless entry system) (See KEYLESS BEEPER REMOVAL/INSTALLATION.)

(10)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

4.  Remove the nuts.

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5.  Remove the insulator.

6.  Set the front heater hose No.1 and No.2 out of the way as shown in the figure.

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

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8.  Disconnect the front 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.

9.  Remove the nut.

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10.  Loosen the nuts.

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11.  Disconnect the rear 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.

12.  Remove the front cooler pipe (HI) from the clip.

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13.  Remove the front cooler pipe (LO) and front cooler pipe (HI) from the clip.

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

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15.  Disconnect the front cooler pipe (HI) and front cooler pipe (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.

16.  Remove the front cooler pipe (LO). Do not allow compressor oil to spill.

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17.  Disconnect the connector.

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18.  Remove the bolts.

19.  Remove the clip.

20.  Set the PCM component out of the way.

21.  Disconnect the connector.

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

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23.  Disconnect the front cooler pipe (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.

24.  Remove the front cooler pipe (HI) from the clip.

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25.  Remove the front cooler pipe (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.

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

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

Rear 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 following parts:

(1)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

(2)  Floor under cover No.2 (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

(3)  Floor under cover No.1 (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

(4)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(5)  Brace bar

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(6)  Tunnel member

(7)  Strut bar

(8)  Insulator (middle) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

4.  Remove the middle pipe from the mount rubber.

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5.  Disconnect the middle pipe from the main silencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Suspend the middle pipe using a cable as shown in the figure.

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7.  Remove the propeller shaft. (4WD) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

8.  Remove the Insulator (front) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Loosen the nut and disconnect the front cooler pipe (HI). Do not allow compressor oil to spill.

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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.

10.  Loosen the nut and disconnect the front cooler pipe (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.

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

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12.  Disconnect the rear 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 clips.

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

16.  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.

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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.

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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)
Front Cooler Hose (LO)	2 ml {2 cc, 0.07 US fl oz}
Front Cooler Hose (HI)	1 ml {1 cc, 0.03 US fl oz}
Front Cooler Pipe (LO)	2 ml {2 cc, 0.07 US fl oz}
Front Cooler Pipe (HI)	2 ml {2 cc, 0.07 US fl oz}
Rear Cooler Pipe	4 ml {4 cc, 0.1 US fl oz}