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REFRIGERANT LINESATC-151
< SERVICE INFORMATION >
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*1 AT C - 2 0 , "Maintenance of Oil Quanti-
ty in Compressor"
*3ATC-167, "Electronic Refrigerant
Leak Detector"
*5 AT C - 3 , "Contaminated Refrigerant"
*2ATC-166, "Checking of Refrigerant
Leaks"
*4ATC-100, "Insufficient Cooling"
WJIA1923E
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ATC-152
< SERVICE INFORMATION >
REFRIGERANT LINES
Component
INFOID:0000000003533292
Front A/C Compressor and Condenser
WJIA1578E
1. High-pressure service valve 2. Grommet 3. High-pressure pipe
4. Refrigerant pressure sensor 5. Condenser 6. Compressor shaft seal
7. High-pressure flexible hose 8. Low-pressure flexible hose 9. Low-pressure service valve
10. Low-pressure pipe 11. Expansion valve (front) 12. Drain hose
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REFRIGERANT LINESATC-153
< SERVICE INFORMATION >
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Rear A/C
NOTE:
Refer to AT C - 4 , "
Precaution for Refrigerant Connection".
WJIA2315E
1. Rear heater and cooling unit assembly 2. Rear A/C pipes 3. Rear A/C heater core pipes
4. Rear heater core hose 5. Rear blower motor 6. Underfloor rear A/C pipes
7. Underfloor rear heater core pipes A. Bolt torque specifications B. Leak checking order (l - r)
C. Tightening torque D. Wrench size E. O-ring size
⇐Front
NOTE: The O-ring size 8 is the high-side and the O-ring size 16 is the low-side.
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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
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REFRIGERANT LINESATC-155
< SERVICE INFORMATION >
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Removal and Installation for Compressor ClutchINFOID:0000000003533294
Magnet Clutch Assembly
REMOVAL
1. Remove the compressor. Refer to ATC-154, "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
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ATC-156
< SERVICE INFORMATION >
REFRIGERANT LINES
5. Remove the pulley using Tool with a small adapter. Position thesmall adapter on the end of the drive shaft and the center of the
puller on the small adapter.
CAUTION:
To prevent deformation of th e pulley groove, the puller
claws should be hooked unde r 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.
2. Install the magnet coil harness clip using a screwdriver. Tool number : KV99233130 (J-29884)
WJIA1017E
WHA212
WHA183
WHA213
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REFRIGERANT LINESATC-157
< SERVICE INFORMATION >
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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 co mpressor 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 pul ley 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
.
10. Install the engine under cover and the splash shield. Tool number : — (J-38873-A)
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WHA184
Tool number : J-44614
WHA229
Clutch disc-to-pulley clearance : 0.3 - 0.6 mm
(0.012 - 0.024 in)
WHA194
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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.