REFRIGERANT LINE REMOVAL/INSTALLATION

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1. Disconnect the negative battery cable.

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

3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7].)

4. Drain the power steering fluid. (R.H.D.) (See POWER STEERING FLUID INSPECTION.)

5. Remove the following parts: (L.H.D.)

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

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

  (3) Windshield wiper motor (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

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

  (5) Air cleaner and fresh air duct component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

  (6) Cooling fan component (See COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZI-3.7].)

6. Remove the following parts: (R.H.D.)

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

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

  (3) Windshield wiper motor (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.)

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

  (5) Engine cover (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)

  (6) Air cleaner and fresh air duct component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

  (7) Dynamic chamber (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

  (8) Front under cover A and B (See FRONT UNDER COVER REMOVAL/INSTALLATION.)

  (9) Middle pipe (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

  (10) Transverse member (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)

  (11) Intermediate shaft installation bolt (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

  (12) Front crossmember, steering gear and linkage component (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.].)

  (13) Power steering fluid tank (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L.H.D.].) (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [R.H.D.].)

7. Disconnect the ATF oil cooler hose from the radiator.

8. Remove the radiator. (See RADIATOR REMOVAL/INSTALLATION [MZI-3.7].)

9. Remove the condenser. (See CONDENSER REMOVAL/INSTALLATION.)

10. Remove the coolant reserve tank retaining bolts and move the coolant reserve tank.

11. Remove the power steering oil pump retaining bolt and nut and move the power steering oil pump. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L.H.D.].) (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [R.H.D.].)

12. Do not allow remaining compressor oil in the piping and connecting parts to spill, and remove in the order indicated in the table.

  Caution
  • If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. Always plug open fittings immediately after removing any refrigeration cycle parts.

R.H.D.

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L.H.D.

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1 | Front cooler pipe No.3 (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note (1).) (See Refrigerant Line Installation Note (2).)
2 | Front cooler hose (LO) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note (1).) (See Refrigerant Line Installation Note (2).)
3 | Front cooler hose (HI) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note (1).) (See Refrigerant Line Installation Note (2).)
4 | Front cooler pipe No.2 (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note (1).) (See Refrigerant Line Installation Note (2).)
5 | Front cooler pipe No.1 (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note (1).) (See Refrigerant Line Installation Note (2).)
6 | Front cooler pipe No.4 (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note (1).) (See Refrigerant Line Installation Note (2).)

13. Remove the following parts, depending on rear cooler pipe to be removed.

  (1) Decoration panel (See DECORATION PANEL REMOVAL/INSTALLATION.)

  (2) Front console box mat (See FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)

  (3) Indicator panel (See INDICATOR PANEL REMOVAL/INSTALLATION.)

  (4) Front console box (See FRONT CONSOLE BOX REMOVAL/INSTALLATION.)

  (5) Dashboard under cover (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)

  (6) Side wall (See SIDE WALL REMOVAL/INSTALLATION.)

  (7) Console panel (See CONSOLE PANEL REMOVAL/INSTALLATION.)

  (8) Console cover (See CONSOLE COVER REMOVAL/INSTALLATION.)

  (9) Console (See CONSOLE REMOVAL/INSTALLATION.)

  (10) Front seat (passenger side) (See FRONT SEAT REMOVAL/INSTALLATION.)

  (11) Bolt

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  (12) Screws

  (13) Rear cooler pipe No.1 bracket.

14. Jack up the vehicle.

15. Remove the nuts and disconnect the presilencer and middle pipe.

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16. Disconnect the rubber hanger.

17. Remove the bolts and presilencer insulator.

18. Remove the bolts.

19. Remove the nut and fastener.

20. Remove the under guard (RH).

21. Remove the transverse member retaining bolts and set the transverse member out of the way. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)

22. Remove the bolt.

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23. Remove the clip.

24. Disconnect rear cooler pipe No.1 and remove rear cooler pipes No.2 and No.1.

25. Install in the reverse order of removal.

26. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.7].)

27. Inspect the ATF level. (See AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AY6A-EL, AY6AX-EL].)

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

Refrigerant Line Removal Note

Block joint type

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

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Refrigerant Line Installation Note (1)

1. Temporarily tighten the joint bolt by hand.

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

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Refrigerant Line Installation Note (2)

1. When installing a new cooler pipe or cooler hose, add a supplemental amount of DENSO OIL8 compressor oil into the refrigeration cycle.

  Supplemental amount (approx. quantity)

  10 ml {10 cc, 0.34 fl oz}