Air Conditioner Additional Kit - Installation Procedure

Air Conditioner Additional Kit:

Installation Procedure

PREPARATION:

Start the engine, turn the AC system on and let the engine idle for approximately 3 minutes. This will ensure that the compressor oil is circulated through the system. After the 3 minute idle, there will be 30 cc of oil in the compressor, 20 cc in the condenser/pipes/tubes, and 10 cc in the evaporator for a system total of 60 cc. In this procedure you will remove and replace the condenser, discharge tube and the compressor, which will remove 50 cc of oil from the system making it unnecessary to drain any oil from the new compressor.

1. Discharge Refrigerant From Refrigeration System.

^ Equipment:

Robinair R-134a Refrigerant Recovery/Recycling Machine (P/N 342000)

2. Remove Radiator Grille.





A. Disengage the 2 claws, and remove the 4 clips and radiator grille.

3. Remove Front Spoiler Pad LH.

A. Remove the 3 screws and spoiler pad.

4. Remove Front Spoiler Pad RH.

A. Remove the 3 screws and spoiler pad.

5. Remove Front Bumper Cover.





A. Put protective tape under the front fender.

B. w/Fog lamp:

Disconnect the fog lamp connectors.

C. Remove the 2 bolts, 8 screws and 3 clips.

D. Using a screwdriver, disengage the 6 claws and remove the bumper cover.

HINT:
Tape the screwdriver tip before use.

6. Remove Low Pitched Horn Assembly.

7. Remove High Pitched Horn Assembly.





8. Remove Hood Lock Assembly.

A. Remove the 3 bolts and hood lock assembly.





9. Remove Hood Lock Support Sub-assembly.

A. Remove the clip.

B. Remove the 2 bolts and hood lock support sub-assembly.





10. Remove Radiator Support Opening Cover.

A. Remove the 2 clips and radiator support opening cover.





11. Disconnect Cooler Refrigerant Discharge Hose No. 1.

A. Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1 from the receiver/condenser assembly.

12. Disconnect Liquid Tube Sub-assembly A.





(The location might be different from the illustration.)

A. Remove the liquid tube sub-assembly A from the receiver/condenser assembly.





13. Remove Receiver/Condenser Assembly.

A. Remove the 2 bolts and the receiver/condenser assembly.





14. Remove Liquid Tube Sub-assembly A.

A. Install the SST to the piping clamp.

^ SST 09870-00025





HINT:
Confirm the direction of the piping clamp claw and SST referring to the illustration on the caution label.

B. Push down on the SST and release the clamp lock.

NOTE:
Be careful not to deform the tube when pushing down on the SST.

C. Pull the SST slightly and push the release lever, and then remove the piping clamp with the SST.





D. Disconnect connector.

E. Remove the bolt and separate the bracket.

F. Remove the liquid tube sub-assembly A.

NOTE:
^ Do not use tools, such as a screwdriver, to remove the tube.

^ Seal the open fittings immediately to keep moisture and foreign material out of the system.





15. Remove Cooler Refrigerant Discharge Hose No. 1.

A. Remove the bolt and disconnect the cooler refrigerant discharge hose No. 1 from the compressor assembly.

B. Remove the cooler refrigerant discharge hose No. 1.





16. Disconnect Suction Hose Sub-assembly.

A. Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly.

NOTE:
Seal the open fittings immediately to keep moisture and foreign material out of the system.

17. Remove Fan and Generator Belt.

18. Remove Engine Under Cover RH.





19. Remove Compressor Assembly.

A. Disconnect the connector.

B. Remove the 4 bolts and the compressor assembly.

20. Install New Compressor Assembly.

A. Install the new compressor assembly with the 4 bolts.

Torque: 25 N.m (255 kgf.cm, 18 in..lbf)





NOTE
Tighten the bolts in the order shown in the illustration to install the compressor assembly.

B. Connect the connector.





21. Install Suction Hose Sub-assembly.

A. Remove the attached vinyl tape from the hose.

B. Apply a sufficient amount of compressor oil to a new 0-ring and the fitting surface of the compressor assembly.

Compressor oil: ND-OIL 8 (or equivalent)

C. Install the 0-ring on the suction hose sub-assembly.

D. Install the suction hose sub-assembly on the compressor assembly with the bolt.

Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf)





22. Install New Cooler Refrigerant Discharge Hose No. 1.

A. Remove the attached cap from the hose.

B. Apply a sufficient amount of compressor oil to a new 0-ring and the fitting surface of the compressor assembly.

Compressor oil: ND-OIL 8 (or equivalent)

C. Install the 0-ring on the cooler refrigerant discharge hose No. 1.

D. Install the cooler refrigerant discharge hose No. 1 on the compressor assembly with the bolt.

Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf)

23. Install Fan and Generator Belt.

24. Install Engine Under Cover RH.

25. Install New Receiver/Condenser Assembly.





A. Install the receiver/condenser assembly with the 2 bolts.

Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf)

26. Install New Radiator Support Opening Cover.





A. Attach the packing to the position shown in the illustration. (When the packing has not been attached).

HINT:
Clean the areas where the packing will be attached.





B. Install the radiator support opening cover with 2 clips.





HINT:
Insert the clips from the back side of the cover (in the opposite direction when removing the cover).

NOTE:
Prevent the packing from coming unstuck when installing the radiator support opening cover.





27. Install Liquid Tube Sub-assembly A.

A. Remove the attached cap from the tube.

B. Lubricate 2 new 0-rings with compressor oil and install them to the hose.

Compressor oil: ND-OIL 8 (or equivalent)

C. Install the liquid tube sub-assembly A and piping clamp.

HINT:
After connection, check the engagement of the piping clamp.





28. Connect Cooler Refrigerant Discharge Hose No. 1.

A. Remove the attached cap from the tube.

B. Sufficiently apply compressor oil to a new 0-ring and hose joint.

Compressor oil: ND-OIL 8 (or equivalent)

C. Install the cooler refrigerant discharge hose No. 1 to the receiver/condenser assembly with the bolt.

Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)





29. Connect Liquid Tube Sub-assembly A.

A. Remove the attached cap from the tube.

B. Lubricate 2 new 0-rings with compressor oil and install them to the hose.

Compressor oil: ND-OIL 8 (or equivalent)

C. Install the liquid tube sub-assembly to the receiver/condenser assembly with the bolt.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

30. Install Hood Lock Support Sub-assembly.

A. Install the hood lock support sub-assembly with the 2 bolts.

Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf)

B. Install the clip.

31. Install Hood Lock Assembly.

A. Install the hood lock assembly with the 3 bolts.

32. Install High Pitched Horn Assembly.

33. Install Low Pitched Horn Assembly.

34. Install Front Bumper Cover.

35. Install Front Spoiler Pad RH.

36. Install Front Spoiler Pad LH.

37. Install Radiator Grille.

38. Charge Refrigerant.

^ Equipment:

Robinair R-134a Refrigerant Recovery/Recycling Machine (P/N 342000)

Specified amount: 380 +/- 30 g (13.4 +/- 1.1 oz.).

39. Remove Instrument Panel.

A. Refer to the Technical Information System (TIS), 2004 model year Scion XA Repair Manual: Instrument Panel/Meter: Instrument Panel Sub-assembly, for the procedures for removing the instrument panel sub-assembly. Stop at section 17d.





40. Replace Cooler Thermistor No. 1.

A. Disengage the 2 claws.

HINT:
Claws can be damaged but be careful not to damage the case.





B. Remove the connector.

C. Replace the cooler thermistor No. 1 with a new one.

NOTE:
If vehicle requires installation of both kits, skip step 41 and go to step 42.

41. Reassemble Instrument Panel.

42. Install Air Conditioner Accessory Assembly.