REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G 2.5]

id071100803038

L.H.D.

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 plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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 plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5].)

4.  Remove the following parts:

(1)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(2)  Battery (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(3)  Battery tray (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(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.)

5.  Remove the nuts.

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6.  Remove the insulator.

7.  Disconnect the front heater hose No.4.

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8.  Disconnect the front heater hose No.3.

9.  Remove the nuts.

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10.  Set the front heater pipe and hose component out of the way as shown in the figure.

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

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12.  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.

13.  Remove the nut.

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14.  Loosen the nut.

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15.  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.

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

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

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18.  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.

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

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

21.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.5].)

22.  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.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5].)

4.  Remove the following parts:

(1)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(2)  Battery (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(3)  Battery tray (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(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.)

5.  Remove the nuts.

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6.  Remove the insulator.

7.  Disconnect the front heater hose No.4.

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8.  Disconnect the front heater hose No.3.

9.  Remove the nuts.

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10.  Set the front heater pipe and hose component out of the way as shown in the figure.

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

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12.  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.

13.  Remove the nut.

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14.  Loosen the nuts.

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15.  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.

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

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

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18.  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.

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

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

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21.  Remove the bolt.

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22.  Disconnect the connector.

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

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24.  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.

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

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26.  Remove the front cooler pipe (HI). Do not allow compressor oil to spill.

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

28.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.5].)

29.  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)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

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

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(6)  Brace bar

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(7)  Tunnel member

(8)  Strut bar

(9)  Insulator (middle) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

4.  Remove the HO2S harness bracket.

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5.  Remove the TWC from the mount rubber.

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6.  Disconnect the TWC from the main silencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

7.  Suspend the TWC using a cable as shown in the figure.

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

9.  Remove the Insulator (front) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

10.  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.

11.  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.

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

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13.  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.

14.  Remove the clips.

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15.  Remove the rear cooler pipe. 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.)

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}

R.H.D.

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 plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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 plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(2)  Battery (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(3)  Battery tray (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

4.  Remove the nuts.

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5.  Remove the insulator.

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

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7.  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.

8.  Remove the nut.

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9.  Loosen the nut.

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10.  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.

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

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

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13.  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.

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

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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.)

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)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(2)  Battery (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(3)  Battery tray (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

4.  Remove the nuts.

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5.  Remove the insulator.

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

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7.  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.

8.  Remove the nut.

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9.  Loosen the nuts.

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10.  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.

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

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12.  Remove the front cooler pipe (LO) and front cooler pipe (HI) 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.  Remove the bolt.

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17.  Disconnect the connector.

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

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19.  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.

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

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21.  Remove the front cooler pipe (HI). Do not allow compressor oil to spill.

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

23.  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)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

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

(5)  Insulator (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

(6)  Brace bar

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(7)  Tunnel member

(8)  Strut bar

(9)  Insulator (middle) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

4.  Remove the HO2S harness bracket.

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5.  Remove the TWC from the mount rubber.

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6.  Disconnect the TWC from the main silencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

7.  Suspend the TWC using a cable as shown in the figure.

ac8ccw00000263

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

9.  Remove the Insulator (front) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

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

ac8ccw00000264

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.  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.

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

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13.  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.

14.  Remove the clips.

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15.  Remove the rear cooler pipe. 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.)

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.

ac9uuw00008193

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.

ac9uuw00008193

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}