REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

id071100803043

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 2.5T].)

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

am6zzw00016011

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.)

am6zzw00016012

7.  Remove 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.

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.)

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

4.  Remove the washer tank bracket. (See WASHER TANK REMOVAL/INSTALLATION.)

5.  Detach the clips.

am6zzw00016013

6.  Remove the bolt.

7.  Disconnect the engine ground.

8.  Disconnect the connector.

am6zzw00016014

9.  Remove the bolts.

10.  Set the PCM component out of the way.

11.  Detach the clips.

am6zzw00016015

12.  Remove the nut.

am6zzw00016016

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

am6zzw00016017

14.  Disconnect the cooler hose (LO) and 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.  Remove the bolt. (See Refrigerant line removal note.)

am6zzw00016018

16.  Disconnect the 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.

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

am6zzw00016019

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

19.  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.)

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

4.  Detach the clips.

am6zzw00016013

5.  Remove the bolt.

6.  Disconnect the engine ground.

7.  Disconnect the connector.

am6zzw00016014

8.  Remove the bolts.

9.  Set the PCM component out of the way.

10.  Detach the clips.

am6zzw00016015

11.  Disconnect the refrigerant pressure sensor connector.

am6zzw00016020

12.  Remove the nut.

13.  Remove the clips.

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

am6zzw00016017

15.  Disconnect the cooler pipe and 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.

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

am6zzw00016021

17.  Disconnect the 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.

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

am6zzw00016022

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

20.  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.

ac4ccw00002366


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.

ac4ccw00002366


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}


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.)

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

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

am6zzw00016011

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.)

am6zzw00016012

7.  Remove 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.

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.)

3.  Remove the following parts:

(1)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
(2)  Washer tank bracket (See WASHER TANK REMOVAL/INSTALLATION.)
(3)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Remove nuts A from underside of vehicle.

am6zzw00016023

5.  Remove nuts B from top side of vehicle.

6.  Remove the insulator.

7.  Detach the clips.

am6zzw00016024

8.  Remove the bolt.

9.  Disconnect the engine ground.

10.  Disconnect the connector.

am6zzw00016025

11.  Remove the bolts.

12.  Set the PCM component out of the way.

13.  Detach the clips.

am6zzw00016015

14.  Remove the nuts.

am6zzw00016026

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

am6zzw00016027

16.  Disconnect the cooler hose (LO) and 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.

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

am6zzw00016018

18.  Disconnect the 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.

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

am6zzw00016028

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

21.  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.)

3.  Remove the following parts:

(1)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
(2)  Front under cover No.2 (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Remove nuts A from underside of vehicle.

am6zzw00016023

5.  Remove nuts B from top side of vehicle.

6.  Remove the insulator.

7.  Detach the clips.

am6zzw00016024

8.  Remove the bolt.

9.  Disconnect the engine ground.

10.  Disconnect the connector.

am6zzw00016025

11.  Remove the bolts.

12.  Set the PCM component out of the way.

13.  Detach the clips.

am6zzw00016015

14.  Disconnect the refrigerant pressure sensor connector.

am6zzw00016029

15.  Remove the nuts.

16.  Remove the clips.

17.  Remove the clip.

am6zzw00016030

18.  Set the heater hose out of the way as shown in the figure.

am6zzw00016031

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

am6zzw00016027

20.  Disconnect the cooler pipe and 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.

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

am6zzw00016021

22.  Disconnect the 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.

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

am6zzw00016032

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

25.  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.

ac4ccw00002366


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.

ac4ccw00002366


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}