Air Conditioning Battery Chiller Removal And Installation/Replacement
Mobile Repair Possible: No
Special Tools Required:
Hose Spring Clamp Removal Tool - 51012018 (or equivalent)
Vacuum and Fill Machine - 81392152473
A/C Vacuum and Recharge System - No part Number (in all procedures)
In some Service Instructions, the coolant hoses are shown with a ring pull (1).
This ring pull (1) is only present on a new hose and must be removed after the coolant hose has been installed.
The coolant hoses installed in the vehicle have only spring band clamps (2).
Failure to follow specified procedures may result in serious injury due to freezing temperatures associated with leaking refrigerant.
- Only properly trained and authorised persons may carry out work on air conditioning systems.
- Always use personal protective equipment (PPE).
Failure to follow specified procedures may result in severe injuries due to burns or scalds.
- Do not commence work until components/liquids have sufficiently cooled down.
- Always use personal protective equipment (PPE).
Contamination or moisture entering the cooling system can lead to malfunction or functional failure.
- The vehicle cooling system and any removed components should be capped/sealed during work to prevent contamination entry.
Removal Procedure:
- Depending on the region, the correct refrigerant must be recovered and recharged. Vietnam market uses R-134a. US/Europe market uses R-1234yf.
Recover refrigerant (US/Europe - R-1234YF). Refer to REFRIGERANT RECOVERY AND RECHARGING (R-1234YF)
- Disconnect the 12V battery negative terminal. Refer to 12V BATTERY NEGATIVE CABLE DISCONNECTION/CONNECTION
- Remove shock tower brace. Refer to SHOCK TOWER BRACE REMOVAL AND INSTALLATION/REPLACEMENT
- Remove air inlet grille panel. Refer to AIR INLET GRILLE PANEL AND EXTENSION REMOVAL AND INSTALLATION/REPLACEMENT
- Drain cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING
- Unlock and disconnect electrical connector (1).
- Remove nut (1).
Torque: 8 Nm
- Pull the lines (2) off of the chiller.
Installation note: Replace O-rings (1).
- Close the openings with plugs (1) to prevent dust and moisture from entering.
- Close the openings with plugs (1) to prevent dust and moisture from entering.
- Loosen the hose clamps (1) and pull the coolant hoses off of the chiller (2).NOTE: Environmental Risk
- Collect and dispose of leaking liquids.
- Observe country-specific disposal regulations.
- Remove 3 bolts (1).
Torque: 12 Nm
- Remove air conditioning battery chiller (2).
Installation Procedure:
Installation note: Use the spring band hose clamp pliers to push the hose on. If replacing with a new hose, you will remove the ring pull (1) to release the clamp. Refer to Fig 1 Make sure that the spring band clamp is aligned inside the marking on the hose . Refer to HOSE CLAMP REMOVAL AND INSTALLATION/REPLACEMENT GUIDELINES - SPRING TYPE
- Installation is the reverse of removal procedure, noting the following.
All fasteners must be tightened to torque specification!
- Fill cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING
- Install air inlet grille panel. Refer to AIR INLET GRILLE PANEL AND EXTENSION REMOVAL AND INSTALLATION/REPLACEMENT
- Install shock tower brace. Refer to SHOCK TOWER BRACE REMOVAL AND INSTALLATION/REPLACEMENT
- Reconnect the 12V battery negative terminal. Refer to 12V BATTERY NEGATIVE CABLE DISCONNECTION/CONNECTION
- Depending on the region, the correct refrigerant must be recovered and recharged. Vietnam market uses R-134a. US/Europe market uses R-1234yf.
Recharge refrigerant (US/Europe - R-1234YF). Refer to REFRIGERANT RECOVERY AND RECHARGING (R-1234YF)
Installation note: If a new component is installed, the refrigerant oil needs to be replenished. Refer to APPROXIMATE FLUID CAPACITIES AND SPECIFICATIONS