Repair Procedure

This bulletin involves replacing the A/C suction line with a revised suction line that has a longer rubber hose section that reduces the moan/whine noise heard in the passenger compartment.

1. For vehicles not equipped with rear heater & A/C, skip to step 6. Raise the wiper arm pivot cover and remove the nut holding the wiper arm to the wiper pivot.

2. Use a suitable two jaw puller to separate the wiper arm from the wiper pivot.

3. Repeat steps 1 and 2 for the other wiper arm.

4. Remove the 4 screws in the grille portion of the cowl cover attaching it to the wiper module.

5. Disengage the 2 quarter turn fasteners located near the wiper pivots.

6. Open the hood and recover the A/C refrigerant.

7. Record the radio station presets, and disconnect the battery negative cable. For vehicles not equipped with rear heater & A/C, skip to step 17.

8. Remove the 4 wing nuts holding the front of the cowl cover to the wiper module.

9. Use a fiber trim stick to disengage the retainer clips, or remove the screws if equipped, attaching the ends of the cowl cover to the fenders.

10. Lift the cowl cover enough to gain access to the right washer hose and disconnect the hose from the washer nozzle.

11. Close the hood, do not latch, and separate the cowl cover from the vehicle.

12. Open the hood and disconnect the wiper unit wire connector from the engine compartment harness.

13. Disconnect the windshield washer hose from the coupling inside the unit and disconnect the drain tubes from the bottom of the unit.

14. Remove the foam sound absorbers from the ends of the unit.

15. Remove the nuts holding the wiper unit to the lower windshield fence and the bolts holding the unit to the dash panel.

CAUTION:
DO NOT ALLOW THE WIPER UNIT TO REST ON THE BRAKE MASTER CYLINDER RESERVOIR, DAMAGE TO THE BRAKE SYSTEM CAN RESULT.

16. Lift the wiper unit from the weld-studs on the lower windshield fence and remove the wiper unit from the vehicle.

17. Remove the serpentine accessory drive belt.





18. Remove the 4 bolts attaching the generator mount bracket and separate the bracket from the vehicle (Figure 1). Rock the generator forward in the vehicle.

19. Remove the nut attaching the ground wire at the cowl.

20. Remove the nut attaching the suction line mounting bracket to the strut tower.

21. Remove the suction line mounting nut from the compressor.

22. Remove the nut attaching the A/C lines to the expansion valve.

23. Remove the torx head stud from the expansion valve.

NOTE:
WHEN SEPARATING THE LINES FROM THE EXPANSION VALVE, DO NOT SCRATCH THE EXPANSION VALVE SEALING SURFACE OR DAMAGE THE PILOT PORTION OF THE LINES.

24. Carefully pull the liquid line sealing plate assembly and suction line from the expansion valve towards the front of the vehicle.

25. For vehicles equipped with rear heater and A/C, disconnect the suction line tube fitting underneath the vehicle and detach the suction line from the dash panel retention bracket. For all vehicles, rock the generator forward in the vehicle and separate the suction line from the vehicle.

26. Replace the 0-ring (P/N 4856770) on the expansion valve end of the liquid line.

27. Verify the 0-rings on the appropriate revised suction line as specified in the Parts Required section of this bulletin are in place and in good condition, then install the suction line to the expansion valve.

28. Install the liquid line/sealing plate assembly to the expansion valve.

29. Hand start the attaching stud through the liquid line plate and into the expansion valve. Torque the stud to 64-96 in.lbs. (8 - 10 Nm).

30. Install the plate nut and torque it to 200-230 in. lbs. (22 - 26 Nm). For vehicles equipped with rear heater & A/C connect the suction line tube fitting underneath the vehicle and tighten to 200 - 230 in. lbs. (23 - 26 Nm) and attach the auxiliary suction line the dash panel retention bracket.

NOTE:
CARE MUST BE TAKEN TO NOT KINK THE HOSE SECTION OF THE A/C LINE DURING INSTALLATION AS THE ADDED HOSE LENGTH IS PRONE TO DISTORT DURING INSTALLATION AND EVACUATION.

31. Connect the suction line to the compressor and torque the attaching nut to 200 - 230 in.lbs. (22 - 26 Nm).

32. Start the evacuation of the A/C system.

33. Install the nut to attach the suction line mounting bracket to the strut tower and the nut to attach the ground wire at the cowl.

34. Install the serpentine accessory drive belt

35. Install the generator mount bracket and torque the 4 attaching bolts to 40 ft. lbs. (54 Nm). For vehicles not equipped with rear heater & A/C, skip to step 45.

36. Install the wiper unit over the weld-studs on the lower windshield fence.

37. Install the nuts that hold the wiper unit to the lower windshield fence and the bolts that hold the unit to the dash panel.

38. Install the foam sound absorbers from the ends of the unit.

39. Connect the windshield washer hose to the coupling inside the unit and connect the drain tubes from the bottom of the unit.

40. Connect the wiper unit wire connector from the engine compartment harness.

41. Close the hood, do not latch, and place the cowl cover in position.

42. Open the hood and lift the cowl cover enough to gain access to the right washer hose and connect the hose to the washer nozzle.

43. Engage the retainer clips or install the screws if equipped, attaching the ends of the cowl cover to the fenders.

44. Install the 4 wing nuts holding the front of the cowl cover to the wiper module.

45. Connect the battery negative cable, program radio station presets and set the clock.

46. Recharge the A/C system.

47. Latch the hood closed. For vehicles not equipped with rear heater & A/C, the repair is now complete.

48. Engage the 2 quarter turn fasteners located near the wiper pivots.

49. Install the 4 screws in the grille portion of the cowl cover attaching it to the wiper module.

50. Verify the wiper motor and linkage are in the parked position.





51. Place the wiper arm in position over the wiper pivot (Figure 2) for proper alignment.

52. Install and torque the nut attaching the wiper arm to the pivot to 26 ft. lbs. (35 Nm).

53. Push the arm cover down into position.

54. Repeat steps 49 thru 51 to install the other wiper arm.