Page 577 of 3383
ATC-176
REFRIGERANT LINES
Revision: November 20092006 QX56
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace the O-rings of the low-pressure flexible hose and high-pressure flexible hose with new
ones, apply compressor oil to the O-rings when installing them.
After recharging the A/C system with refrigerant, check for leaks.
Removal and Installation for Compressor ClutchEJS003YU
Magnet Clutch Assembly
REMOVAL
1. Remove the compressor. Refer to ATC-175, "Removal and Installation for Compressor" .
2. Remove the center bolt while holding the clutch disc stationary using Tool as shown.
3. Remove the clutch disc.
4. Remove the snap ring using external snap ring pliers or suitable tool.
WJIA0372E
1. Magnet clutch assembly 2. Magnet coil 3. Pulley
4. Clutch disc 5. Snap ring 6. Thermal protector (built in)
7. Compressor
Tool number : J-44614
WHA228
RHA072C
Page 578 of 3383

REFRIGERANT LINESATC-177
C
DE
F
G H
I
K L
M A
B
AT C
Revision: November 2009 2006 QX56
5. Remove the pulley using Tool with a small adapter. Position the
small adapter on the end of the drive shaft and the center of the
puller on the small adapter.
CAUTION:
To prevent deformation of the pulley groove, the puller
claws should be hooked under the pulley groove and not
into the pulley groove.
6. Remove the magnet coil harness clip using a screwdriver, remove the three magnet coil fixing screws and remove the
magnet coil.
INSPECTION
Clutch Disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.
Pulley
Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving,
replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable
solvent before reinstallation.
Coil
Check magnet coil for loose connections or any cracked insulation.
INSTALLATION
1. Install the magnet coil.
CAUTION:
Be sure to align the magnet coil pin with the hole in the
compressor front head.Tool number : KV99233130 (J-29884)
WJIA1017E
WHA212
WHA183
WHA213
Page 579 of 3383

ATC-178
REFRIGERANT LINES
Revision: November 20092006 QX56
2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install
the snap ring using snap ring pliers.
4. Install the clutch disc on the compressor shaft, together with the original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc from turning and tighten the bolt to specification.
CAUTION:
After tightening the clutch pulley bolt, check that the clutch
pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc as shown.
7. If the specified clearance is not obtained, replace the adjusting spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer to EM-13, "
DRIVE BELTS" .
10. Install the engine under cover and the splash shield. Tool number : — (J-38873-A)
WJIA1016E
WHA184
Tool number : J-44614
WHA229
Clutch disc-to-pulley clearance : 0.3 - 0.6 mm
(0.012 - 0.024 in)
WHA194
Page 580 of 3383

REFRIGERANT LINESATC-179
C
DE
F
G H
I
K L
M A
B
AT C
Revision: November 2009 2006 QX56
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.
Removal and Installation for Low-pressure Flexible HoseEJS003YV
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer to EM-15, "
AIR CLEANER AND AIR DUCT"
3. Remove the cowl top extension. Refer to EI-18, "COWL TOP" .
4. Discharge the refrigerant. Refer to ATC-171, "
HFC-134a (R-134a) Service Procedure" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
5. Remove the low-pressure flexible hose.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for High-pressure Flexible HoseEJS003YW
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer to EM-15, "
AIR CLEANER AND AIR DUCT" .
3. Discharge the refrigerant. Refer to ATC-171, "
HFC-134a (R-134a) Service Procedure" .
4. Remove the high-pressure flexible hose. CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for High-pressure PipeEJS003YX
REMOVAL
1. Remove the cowl top extension. Refer to EI-18, "COWL TOP" .
2. Disconnect the battery negative terminal and positive battery terminal.
3. Reposition the IPDM E/R aside.
4. Remove the front right wheel and tire assembly. Refer to WT-7, "
Rotation" .
5. Position aside the front floor insulator.
6. Discharge the refrigerant. Refer to ATC-171, "
HFC-134a (R-134a) Service Procedure" .
7. Remove the low pressure pipe. Refer to ATC-180, "
Removal and Installation for Low-pressure Pipe" .
8. Remove the high-pressure pipe. CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
Page 581 of 3383

ATC-180
REFRIGERANT LINES
Revision: November 20092006 QX56
CAUTION:
Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Low-pressure PipeEJS003YY
REMOVAL
1. Discharge the refrigerant. Refer to ATC-171, "HFC-134a (R-134a) Service Procedure" .
2. Remove the cowl top and the cowl top extension. Refer to EI-18, "
COWL TOP" .
3. Remove the low-pressure pipe. CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Replace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Rear High- and Low-pressure A/C and Heater Core
Pipes
EJS005Y8
REMOVAL
1. Discharge the refrigerant. Refer to ATC-171, "HFC-134a (R-134a) Service Procedure" .
2. Drain the coolant from the engine cooling system. Refer to CO-10, "
Changing Engine Coolant" .
3. Disconnect the underfloor rear heater hoses (1 and 2) from the rear heater pipes underneath the vehicle.
⇐: Front
4. Remove the rear high- and low-pressure pipes bolt (A) to dis- connect the rear high- and low-pressure pipes from the under-
floor rear high- and low-pressure pipes underneath the vehicle.
CAUTION:
Cap or wrap the joint of the pipes with suitable material
such as vinyl tape to avoid the entry of air.
5. Remove the rear high- and low-pressure pipes nuts (B) under- neath the vehicle.
NOTE:
The remaining steps are performed inside the rear luggage area of the vehicle.
6. Remove the luggage side finisher lower RH. Refer to EI-40, "
LUGGAGE FLOOR TRIM" .
7. Disconnect the rear heater core hoses (1 and 2) from the rear heater core (3).
⇐: Front
WJIA2310E
WJIA2311E
Page 582 of 3383

REFRIGERANT LINESATC-181
C
DE
F
G H
I
K L
M A
B
AT C
Revision: November 2009 2006 QX56
8. Remove the rear high- and low-pressure pipes bracket bolt (A)
to release the bracket.
Rear blower motor (1)
⇐: Front
9. Remove the rear high- and low-pressure pipes bolt (A) to dis- connect the rear high- and low-pressure pipes from the rear
expansion valve (1).
⇐: Front
CAUTION:
Cap or wrap the joint of the pipes with suitable material
such as vinyl tape to avoid the entry of air.
10. Disconnect the following electrical connectors:
Rear air mix door motor (1)
Rear blower motor resistor (2)
Rear blower motor (3)
⇐ : Front
11. Disconnect the ducts from the rear heater and cooling unit assembly. Refer to ATC-166, "
Components" .
12. Remove the rear heater and cooling unit assembly. CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
13. Remove the rear high- and low-pressure A/C pipes.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Replace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Underfloor Rear High- and Low-pressure A/C and
Heater Core Pipes
EJS005Y9
REMOVAL
1. Drain the coolant from the engine cooling system. Refer to CO-10, "Changing Engine Coolant" .
2. Disconnect the battery negative terminal.
3. Disconnect the generator harness.
4. Discharge the refrigerant. Refer to ATC-171, "
HFC-134a (R-134a) Service Procedure" .
WJIA2312E
WJIA2313E
WJIA2314E
Page 583 of 3383

ATC-182
REFRIGERANT LINES
Revision: November 20092006 QX56
5. Remove the front and rear bumper fascia. Refer to EI-13, "FRONT BUMPER" (front), EI-15, "REAR
BUMPER" (rear).
6. Reposition the front fender protector out of the way. Refer to EI-23, "
FENDER PROTECTOR" .
7. Disconnect the chassis harness connector.
8. Remove the spare wheel and tire.
9. Remove the tailpipe and tailpipe hanger bracket. Refer to EX-3, "
Removal and Installation" .
10. Remove the seatbelt latch anchor. Refer to RSU-26, "
Components" .
11. Remove the front floor heat shield.
12. Disconnect each end of the underfloor rear high- and low-pressure A/C and heater core pipes. Refer to ATC-173, "
Components" .
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
13. Set two suitable jacks at the RH body mount points to support the vehicle body when it is separated from the RH side of the frame.
14. Remove the RH body mount bolts. Refer to BL-159, "
Body Mounting" .
15. Use the vehicle hoist to lower the RH side of the frame from the RH side of the body [approximately 305 mm (12 in)] until there is sufficient clearance to remove the underfloor rear high- and low-pressure A/C
and heater core pipes from between the body and the frame.
16. Remove the underfloor rear high- and low-pressure A/C and heater core pipes from the back of the vehi- cle.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Replace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Refrigerant Pressure SensorEJS003YZ
REMOVAL
1. Discharge the refrigerant. Refer to ATC-171, "HFC-134a (R-134a) Service Procedure" .
2. Disconnect the refrigerant pressure sensor electrical connector and remove the refrigerant pressure sensor from the condenser.
CAUTION:
Be careful not to damage the condenser fins.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Be careful not to damage the condenser fins.
Replace the O-ring of the refrigerant pressure sensor with a new one, then apply compressor oil to
it when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for CondenserEJS003Z0
REMOVAL
1. Discharge the refrigerant. Refer to ATC-171, "HFC-134a (R-134a) Service Procedure" .
LJIA0145E
Page 584 of 3383

REFRIGERANT LINESATC-183
C
DE
F
G H
I
K L
M A
B
AT C
Revision: November 2009 2006 QX56
2. Remove the radiator. Refer to CO-14, "RADIATOR" .
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
3. Disconnect the high-pressure flexible hose and the high-pressure pipe from the condenser. CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
4. Disconnect the refrigerant pressure sensor connector.
Remove the refrigerant pressure sensor from the condenser
as necessary.
5. Lift the condenser out of the mounting grommets to remove the condenser.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-173, "
Components" .
CAUTION:
Replace the O-rings of the high-pressure pipe, refrigerant pressure sensor, and high-pressure
flexible hose with new ones, then apply compressor oil to them when installing them.
After charging refrigerant, check for leaks.
Replace the grommets as necessary.
LJIA0145E