OIL
ATC-21
< SERVICE INFORMATION >
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1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.
No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
2. Connect recovery/recycling equipment to vehicle. Confir m refrigerant purity in supply tank using recovery/
recycling equipment and refrigerant identifier. If NG, refer to AT C - 3 , "
Contaminated Refrigerant".
3. Confirm refrigerant purity in vehicle A/C system using recovery/recycling equipment and refrigerant identi-
fier. If NG, refer to AT C - 3 , "
Contaminated Refrigerant".
4. Discharge refrigerant into the refrigerant recove ry/recycling equipment. Measure oil discharged into the
recovery/recycling equipment.
5. Drain the oil from the “old” (removed) compress or into a graduated container and recover the amount of
oil drained.
6. Drain the oil from the “new” compressor into a separate, clean container.
7. Measure an amount of new oil installed equal to am ount drained from “old” compressor. Add this oil to
“new” compressor through the suction port opening.
8. Measure an amount of new oil equal to the amount recovered during discharging. Add this oil to “new” compressor through the suction port opening.
9. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) of oil at this
time.
CAUTION:
Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of oil if only replacing the compressor.
1. New compressor 2. Old compressor 3. Recovery/recycling equipment
4. Measuring cup X 5. Measuring cup Y 6. New oil
A. Drain oil from the new compressor
into clean container B. Record amount of oil recovered C.
Add an additional 5 m (0.2 US fl oz,
0.2 Imp fl oz) of new oil when replacing
liquid tank
D. Install new oil equal to recorded amounts in measuring cups X plus Y
WJIA1716E
ATC-134
< SERVICE INFORMATION >
HEATER & COOLING UNIT ASSEMBLY
5. Disconnect the front heater hoses from the front heater core.
6. Disconnect the high/low pressure pipes from the front expansion valve.
7. Remove the instrument panel and console panel. Refer to IP-10, "
Removal and Installation".
8. Remove the steering column. Refer to PS-10
.
9. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (J/B) electrical connectors. Refer to PG-3
.
10. Disconnect the steering member from each side of the vehicle body.
11. Remove the front heater and cooling unit assembly with it attached to the steering member, from the vehi-
cle.
CAUTION:
Use care not to damage the seats and interior tr im panels when removing the front heater and
cooling unit assembly with it at tached to the steering member.
12. Remove the front heater and cooling unit assembly from the steering member.
Installation
Installation is in the reverse order of removal.
CAUTION:
• Replace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply com-
pressor oil to it when installing it.
• After charging the refrigerant, check for leaks.
NOTE:
• Fill the engine cooling system with the s pecified coolant mixture. Refer to MA-12, "
Changing Engine Cool-
ant".
• Recharge the A/C system. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
REAR HEATER AND COOLING UNIT ASSEMBLY
Removal
1. Discharge the refrigerant from the A/C system. Refer to ATC-150, "HFC-134a (R-134a) Service Proce-
dure".
2. Drain the coolant from the engine cooling system. Refer to MA-12, "
Changing Engine Coolant".
3. Disconnect the rear heater core hoses from the rear heater core.
4. Disconnect the rear A/C pipes from the rear expansion valve.
5. Remove the luggage side finisher lower RH. Refer to EI-34
.
6. Disconnect the following electrical connectors: • Rear blower motor
• Rear blower motor resistor
• Rear air mix door motor
7. Disconnect the ducts from the rear heater and cooling unit assembly.
8. Remove the rear heater and cooling unit assembly.
Installation
Installation is in the reverse order of removal.
CAUTION:
• Replace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply com-
pressor oil to it when installing it.
• After charging the refrigerant, check for leaks.
NOTE:
• Fill the engine cooling system with the s pecified coolant mixture. Refer to MA-12, "
Changing Engine Cool-
ant".
• Recharge the A/C system. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
LJIA0021E
ATC-150
< SERVICE INFORMATION >
REFRIGERANT LINES
REFRIGERANT LINES
HFC-134a (R-134a) Service ProcedureINFOID:0000000003533291
SETTING OF SERVICE TOOLS AND EQUIPMENT
Discharging Refrigerant
WARNING:
Avoid breathing A/C refrigerant and oil vapor or mist. Exposure may irritate eyes, nose and throat.
Remove HFC-134a (R-134a) refrigerant from the A/C system using certified service equipment meeting
requirements of SAE J2210 HFC-134a (R-134a) r ecycling equipment or SAE J2201 HFC-134a (R-134a)
recovery equipment. If an accident al system discharge occurs, ventila te the work area before resum-
ing service. Additional h ealth and safety information may be obtain ed from the refrigerant and oil man-
ufacturers.
Evacuating System and Charging Refrigerant
1. Shut-off valve 2. A/C service valve 3. Recovery/recycling equipment
WJIA0579E
1. Shut-off valve 2. A/C service valve 3. Recovery/recycling equipment
4. Refrigerant container (HFC-134a) 5. Weight scale (J-39650) 6. Evacuating vacuum pump (J-39699)
7. Manifold gauge set (J-39183)
WJIA0580E
ATC-154
< SERVICE INFORMATION >
REFRIGERANT LINES
Removal and Installation for Compressor
INFOID:0000000003533293
A/C Compressor Mounting
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Remove the front right wheel and tire assembly. Refer to WT-7, "
Rotation".
3. Remove the engine under cover and the splash shield using power tool.
4. Remove the engine air cleaner and air ducts. Refer to EM-15
.
5. Remove the drive belt. Refer to EM-13
.
6. Disconnect the compressor electrical connector.
7. Disconnect the high-pressure flexible hose and low- pressure flexible hose from the compressor.
CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
8. Remove the compressor bolts and nut using power tools.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace the O-rings of the low-pressure flexibl e 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.
WJIA0958E
ATC-158
< SERVICE INFORMATION >
REFRIGERANT LINES
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 HoseINFOID:0000000003533295
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer to EM-15
.
3. Remove the cowl top extension. Refer to EI-17
.
4. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial 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-152, "
Component".
CAUTION:
• Replace the O-ring of the low-pr essure 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 HoseINFOID:0000000003533296
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer to EM-15
.
3. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
4. Remove the high-pressure flexible hose. CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
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 PipeINFOID:0000000003533297
REMOVAL
1. Remove the cowl top extension. Refer to EI-17.
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-150, "
HFC-134a (R-134a) Service Procedure".
7. Remove the low-pressure pipe. Refer to ATC-159, "
Removal and Installation for Low-Pressure Pipe".
8. Remove the high-pressure pipe. CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
REFRIGERANT LINESATC-159
< SERVICE INFORMATION >
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Refer to ATC-152, "Component".
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 PipeINFOID:0000000003533298
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Remove the cowl top and the cowl top extension. Refer to EI-17
.
3. Remove the low-pressure pipe. CAUTION:
Cap or wrap the joint of the pipes with suitable material such as viny l tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
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
INFOID:0000000003533299
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Drain the coolant from the engine cooling system. Refer to CO-9, "
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-pressu re pipes underneath the vehicle.
CAUTION:
Cap or wrap the joint of the pipes with suitable material
such as vinyl tape to avo id 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-39
.
7. Disconnect the rear heater core hoses (1 and 2) from the rear heater core (3).
•⇐ : Front
WJIA2310E
WJIA2311E
ATC-160
< SERVICE INFORMATION >
REFRIGERANT LINES
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-145, "
Component".
12. Remove the rear heater and cooling unit assembly. CAUTION:
Cap or wrap the joint of the pipes with suitable material such as viny l 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-152, "
Component".
CAUTION:
• Replace the O-ring of th e 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 Installati on for Underfloor Rear High- and Low-Pressure A/C and Heater
Core Pipes
INFOID:0000000003533300
REMOVAL
1. Drain the coolant from the engine cooling system. Refer to CO-9, "Changing Engine Coolant".
2. Disconnect the battery negative terminal.
3. Disconnect the generator harness.
4. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
WJIA2312E
WJIA2313E
WJIA2314E
REFRIGERANT LINESATC-161
< SERVICE INFORMATION >
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5. Remove the front and rear bumper fascia. Refer to EI-12 (front), EI-14 (rear).
6. Reposition the front fender protector out of the way. Refer to EI-22
.
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-21, "
Component".
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-152, "
Component".
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as viny l 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-135, "
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-152, "
Component".
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 SensorINFOID:0000000003533301
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Disconnect the refrigerant pressu re 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-152, "
Component".
CAUTION:
• Be careful not to damage the condenser fins.
• Replace the O-ring of the refrig erant 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 CondenserINFOID:0000000003533302
REMOVAL
1. Discharge the refrigerant. Refer to .
LJIA0145E