Handling Refrigerant Lines and Fittings

IMPORTANT: See 6. DUAL O-RING JOINT before disconnecting any fitting. Service and Repair

When opening the refrigeration system, the work area should be well ventilated. Welding or steam cleaning operations should not be done on or near refrigeration system lines or other air conditioning parts on the vehicle.

All metal tubing lines should be free of dents or kinks to prevent loss of system capacity due to line restriction.
^ The flexible hose lines should never be bent to a radius of less than 4 times the diameter of the hose.
^ The flexible hose lines should never be allowed to come within a distance of 6.5mm (2.5 inches) of the exhaust manifold.
^ Flexible hose lines should be inspected regularly for leaks or brittleness and replaced with new lines if deterioration or leaking is found.
^ When disconnecting any fitting in the refrigerant system, the system must be discharged of all Refrigerant-134a. However, proceed very cautiously, regardless of the gage readings. Open very slowly, keeping your face and hands away so that no injury can occur. If pressure is noticed when a fitting is loosened, allow it to bleed OFF very slowly.

NOTE: Alcohol should never be used in the refrigeration system in an attempt to remove moisture. Damage to system components could occur:

^ If any refrigerant line is opened to the atmosphere, it should be immediately capped to prevent the entrance of moisture and dirt. This can cause internal compressor wear or plugged lines, in the condenser and evaporator core and expansion (orifice) tubes or compressor inlet screens.
^ Sealing caps should be removed from subassemblies just before making connections for final assembly. A small amount of clean PAG refrigerant oil should be used on all tube and hose joints. The oil will aid in assembly and help to provide a leak proof joint. O-rings and seats must be in perfect condition because a burr or a piece of dirt can cause a refrigerant leak.
^ The use of the proper wrenches when making connections on O-ring fittings, is important. The use of improper wrenches may damage the connection. The opposing fitting should always be backed up with a wrench to prevent distortion of connection lines or components. When connecting the flexible hose connections, it is important that the swagged fitting and the flare nut, as well as the coupling to which it is attached, be held at the same time using three different wrenches to prevent turning the fitting and damaging the seat.
^ Torque all tubing connections to 34 N.m (25 lb.ft.).