A/C 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 the refrigeration system.

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





2. Remove the radiator grille. Remove the 3 clips and radiator grille.

3. Remove the front fender liner LH.

A. Remove the 2 screws.

B. Partially remove the fender liner.

HINT:
Do not remove the fender liner completely but partially so that the bumper cover can be removed.

4. Remove the front fender liner RH.

HINT:
Use the same procedures for the RH and LH sides.





5. Remove the front bumper cover.

A. Put protective tape under the front fender.

B. Remove the clip and 2 bolts from the upper side of the bumper cover.

C. Using a screwdriver, disengage the 2 claws and remove the 2 bolts, 6 screws and bumper cover.

HINT:
Tape the screwdriver tip before use.





6. Remove the radiator support seal. Remove the 2 clamps and the radiator support seal.

7. Remove the low pitched horn assembly.





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





9. Disconnect the cooler refrigerant discharge hose No. 1.

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





10. Disconnect the liquid tube sub-assembly A.

(The location might be different from the illustration.)

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





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





12. Remove the 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.





13. Remove the 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.





14. Disconnect the 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.

15. Remove the fan and the generator belt.

16. Remove the engine under cover RH.





17. Remove the compressor assembly.

A. Disconnect the connector.

B. Remove the 4 bolts and the compressor assembly.

18. Install the NEW compressor assembly.

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

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





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

B. Connect the connector.





19. Install the 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)





20. Install the 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)

21. Install the fan and the generator belt.





22. Install the engine under cover RH.

23. Install the NEW receiver/condenser assembly. Install the receiver/condenser assembly with the 2 bolts.

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

24. Install the 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.





25. Install the 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.





26. Connect the cooler 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)





27. Connect the 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)





28. Install the 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.

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

30. Install the high pitched horn assembly.

31. Install the low pitched horn assembly.

32. Install the front bumper cover.

33. Install the front spoiler pad RH.

34. Install the front spoiler pad LH.

35. Install the radiator grille.

36. Charge refrigerant.

Equipment: Robinair R-134a Refrigerant Recovery/Recycling Machine (P/N 342000) Specified amount: 380 +/- 30 g (13.4 +/- 1.1 oz.)

37. Remove the instrument panel.

Refer to the Technical Information System (TIS), 2004 model year Scion xB Repair Manual: Instrument Panel/Meter: Instrument Panel Sub-assy for the procedures for removing the instrument panel sub-assembly. Stop at section 16e.

38. Replace the 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 39 and go to step 40.

39. Reassemble the instrument panel.

40. Install the air conditioner accessory assembly.