REFRIGERANT LINE REMOVAL/INSTALLATION

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1. Disconnect the negative battery cable.

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

3. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF, L5].)

4. Remove the refrigerant pressure sensor connector.

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Caution

• If moisture or foreign material 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 material out of the cycle.

6. Install in the reverse order of removal.

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

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1

Cooler hose (HI)

(See Refrigerant Line Removal Note.)

(See Refrigerant Line Installation Note.)

2

Cooler hose (LO)

(See Cooler Hose (LO) Installation Note.)

(See Refrigerant Line Removal Note.)

(See Refrigerant Line Installation Note.)

3

Cooler pipe

(See Cooler Pipe Installation Note.)

(See Refrigerant Line Removal Note.)

(See Refrigerant Line Installation Note.)

LF, MZR 2.0 DISI i-stop

1. Disconnect the negative battery cable.

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

3. Disconnect the refrigerant pressure sensor connector.

4. Remove the bolt.

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5. Remove the cooler hose (HI) and cooler hose (LO).

6. Remove the P/S fluid reserve tank.

7. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [LF, L5].) (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

8. Remove the splash shield.

9. Remove the charge air cooler cover.

10. Remove the insulator.

11. Remove the cooler pipe.

Caution

12. Install in the reverse order of removal.

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

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Z6, ZY

1. Disconnect the negative battery cable.

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

3. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [ZY, Z6].)

4. Disconnect the refrigerant pressure switch connector.

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Caution

6. Install in the reverse order of removal.

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

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MZ-CD 1.6 (Y6)

1. Disconnect the negative battery cable.

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

3. Remove the coolant reserve tank.

4. Disconnect the refrigerant pressure switch connector. (See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) (See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Caution

6. Install in the reverse order of removal.

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

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MZR-CD 2.2

1. Disconnect the negative battery cable.

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

3. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

4. Disconnect the refrigerant pressure switch connector.

5. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Caution

6. Install in the reverse order of removal.

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

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L3 Turbo

1. Disconnect the negative battery cable.

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

3. Remove the engine cover.

4. Remove the insulator.

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5. Remove the nut and disconnect the vacuum pipe then set the vacuum pipe shown in the figure out of the way. (R.H.D.)

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6. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [L3 Turbo].)

7. Remove the refrigerant pressure sensor connector.

8. Remove in the order indicated in the table. Do not allow compressor oil to spill.

Caution

9. Install in the reverse order of removal.

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

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Refrigerant Line Removal Note

Block joint type

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

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Spring-lock coupling type

1. Set the SST.

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2. While looking through the inspection hole of the SST, insert the protruding part of the SST until it makes contact with the cage section.

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3. Use the SST to disconnect the male pipe or hose from the female by pulling the male pipe or hose.

Note

• The male pipe or hose can be disconnected easily from the female pipe by pulling from the male pipe or hose while maintaining the pressure of the protruding part of the SST.

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Refrigerant Line Installation Note

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

2. Tighten the joints.

Block joint type

1. Tighten the bolt of joint 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, then tighten the connection bolt or nut with a torque wrench.

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Spring-lock coupling type

1. Connect the male pipe or hose by twisting it onto female pipe until the garter spring at the male pipe or hose is over the flared end of female pipe.

Note

• When the male pipe or hose is replaced, the indicator ring comes out after connecting to indicate that it is locked.

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Cooler Hose (LO) Installation Note

1. After replacing the cooler hose (LO), add compressor oil to the refrigeration cycle.

Supplemental oil amount (approx. quantity)

10 ml {10 cc, 0.32 fl oz}

Cooler Pipe Installation Note

1. After replacing the cooler pipe, add compressor oil to the refrigeration cycle.

Supplemental oil amount (approx. quantity)

5 ml {5 cc, 0.16 fl oz}

1	Cooler hose (HI) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)
2	Cooler hose (LO) (See Cooler Hose (LO) Installation Note.) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)
3	Cooler pipe (See Cooler Pipe Installation Note.) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)

1	Cooler hose (HI) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)
2	Cooler pipe No.2 (See Cooler Pipe Installation Note.) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)
3	Cooler hose (LO) (See Cooler Hose (LO) Installation Note.) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)
4	Cooler pipe No.1 (See Cooler Pipe Installation Note.) (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)