Start By:
- Remove the right side engine enclosure. Refer to Disassembly and Assembly, "Sound Suppression - Remove and Install".
Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. |
- Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG2500, "Air Conditioning Tools" for the correct tools.
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Illustration 1 g01392126 - Remove cover (1) and filter (2).
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Illustration 2 g01392160 - Remove bolts (3). Remove cover (4).
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Illustration 3 g01392402 - Remove bolts (5).
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Illustration 4 g01392409 - Remove bolts (6).
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Illustration 5 g01392416 - Remove cover (7).
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Illustration 6 g01392420 - Remove bolt (9). Remove panel assembly (8).
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Illustration 7 g01392425 - Turn valves (10) to the OFF position.
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Illustration 8 g01392447 - Loosen clamp (11) and disconnect hose (12). Disconnect harness assembly (13).
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Illustration 9 g01392479 - Disconnect hose assemblies (14). Loosen clamp (15) and disconnect hose (16).
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Illustration 10 g01392577 - Remove nuts (17) from both sides of air conditioner assembly (18).
- Use two people in order to remove air conditioner assembly (18). The weight of air conditioner assembly (18) is approximately
32 kg (70 lb) .Show/hide tableIllustration 11 g01392590 - Remove bolts (20). Remove plate (19).
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Illustration 12 g01392603 - Remove bolts (21). Remove plate (22).
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Illustration 13 g01392610 - Remove bolt (23).
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Illustration 14 g01392616 - Mark the position of tube (25) and position tube (25) out of the way.
- Remove bolts (26) and remove evaporator coil (24).
Note: Cleanliness is an important factor. Before you begin the installation procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
- Position evaporator coil (24) and install bolts (26). Reposition tube (25) into the marked locations.
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Illustration 16 g01392610 - Install bolts (23).
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Illustration 17 g01392603 - Position plate (22) and install bolts (21).
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Illustration 18 g01392590 - Position plate (19) and install bolts (20).
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Illustration 19 g01392577 - Use two people in order to position air conditioner assembly (18). The weight of air conditioner assembly (18) is approximately
32 kg (70 lb) . - Install nuts (17) on both sides of air conditioner assembly (18).
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Illustration 20 g01392479 - Connect hose assemblies (14). Connect hose (16) and tighten clamp (15).
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Illustration 21 g01392447 - Connect harness assembly (13). Connect hose (12) and tighten clamp (11).
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Illustration 22 g01392425 - Turn valves (10) to the ON position.
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Illustration 23 g01392420 - Position panel assembly (8) and install bolt (9).
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Illustration 24 g01392416 - Install cover (7).
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Illustration 25 g01392409 - Install bolts (6).
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Illustration 26 g01392402 - Install bolts (5).
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Illustration 27 g01392160 - Position cover (4) and install bolts (3).
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Illustration 28 g01392126 - Install filter (2) and install cover (1).
- Charge the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG2500, "Air Conditioning Tools" for the correct tools.
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Illustration 15 | g01392616 |
End By:
- Install the right side engine enclosure. Refer to Disassembly and Assembly, "Sound Suppression - Remove and Install".