REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5]

id071100803037

Replacement Part

O-ring (cooler hose (HI))

Quantity: 2

Location of use: Cooler hose (HI)

O-ring (cooler hose (LO))

Quantity: 2

Location of use: Cooler hose (LO)

O-ring (cooler pipe)

Quantity: 2

Location of use: Cooler pipe

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 plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)].) (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

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

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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.)

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

Caution

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.)

4. Remove the nut.

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

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

Caution

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

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

Caution

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

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

11. 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.)

4. Remove the nut.

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5. Remove the clips.

6. Disconnect the refrigerant pressure sensor connector.

7. Remove the bolt.

8. Disconnect the engine ground.

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

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

Caution

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

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

Caution

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

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

15. 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)

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 (HI)

1 ml {1 cc, 0.03 US fl oz}

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 (HI)	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.)

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

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

Caution

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

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

Caution

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.)

4. Remove the nuts.

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5. Remove the insulator.

6. Remove the nut.

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7. Remove the clip.

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

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

Caution

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

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

Caution

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

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

14. 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.)

4. Remove the nuts.

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5. Remove the insulator.

6. Remove the nut.

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7. Remove the clips.

8. Disconnect the refrigerant pressure sensor connector.

9. Remove the bolt.

10. Disconnect the engine ground.

11. Remove the clip.

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

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

Caution

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

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

Caution

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

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

18. 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.