Repair Procedure A

A/C Compressor, Discharge/Suction Lines and Receiver/Drier Replacement.

NOTE:
VEHICLES EQUIPPED WITH SINGLE A/C SYSTEM DO NOT REQUIRE SUCTION LINE REPLACEMENT.

1. Open the hood.

2. Vehicles equipped with single A/C system proceed to step 8. Vehicles equipped with dual A/C system proceed to next step.

3. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover.

4. Start and run the engine until it stalls.

5. Attempt to restart the engine until it will no longer run.

6. Turn the ignition key to the "OFF" position.

7. Install the fuel pump relay to the PDC.

8. Disconnect the negative battery cable.

9. Remove the air cleaner assembly to gain access to the A/C liquid and suction lines.

10. Using an approved A/C refrigerant recovery machine, evacuate the A/C system of all R-134a refrigerant.

NOTE:
FOLLOW INSTRUCTIONS SUPPLIED WITH THE A/C RECOVERY EQUIPMENT.

WARNING:
THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. ALWAYS WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM.

11. Disconnect both liquid lines from the receiver/drier.

NOTE:
CLEAN THE TOP OF THE RECEIVER/DRIER BEFORE REMOVING THE LIQUID LINES.

CAUTION:
SOME RESIDUAL SYSTEM PRESSURE MAY BE PRESENT WHEN REMOVING THE LIQUID LINES FROM THE RECEIVER/DRIER. AVOID BREATHING THE REFRIGERANT AND/OR REFRIGERANT OIL VAPORIMIST.

12. Remove the receiver/drier by sliding the receiver/drier from the mounting bracket. Save the receiver/drier for later inspection.

13. Vehicles with dual A/C system, proceed to next step. Vehicles with single A/C system, proceed to step 16.





14. Disconnect the right side wiper module drain tube and relocate it to gain access to the expansion valve (Fig. 1).

15. Disconnect the suction line from the expansion valve tapping plate.

16. Disconnect the suction line from the A/C compressor.





17. Disconnect the discharge line from the A/C compressor (Fig. 2).

18. RS vehicles proceed to next step. RG vehicles proceed to step 22.

NOTE:
RG VEHICLES DO NOT USE THE NEW DISCHARGE LINE INCLUDED IN THE PARTS KIT. DISCARD THE NEW DISCHARGE LINE.

19. Remove the right side (passenger side) headlamp assembly.





20. Accessing the fastener through the headlamp opening, disconnect the discharge line from the condenser (Fig. 3)

21. Remove and discard the discharge line from the vehicle.

22. Lift the vehicle on an appropriate hoist.

23. Remove the right side (passenger side) lower wheel opening splash shield.

24. Remove the serpentine drive belt.





25. Disconnect the clutch coil connector at the A/C compressor (Fig. 4)

26. Remove the A/C compressor from the vehicle and set the compressor aside (Fig. 4).

NOTE:
AVOID SPILLING ANY COMPRESSOR OIL DURING REMOVAL. THE OIL WILL NEED TO BE MEASURED TO ENSURE THE CORRECT AMOUNT OF OIL IS ADDED TO THE NEW COMPRESSOR.

27. Vehicles with single A/C system, proceed to step 29. Vehicle with dual A/C system, proceed to next step.





28. Remove the tie strap on the liquid/suction lines (Fig. 5).

29. Separate the front suction line extension from the rear underbody suction line (Fig. 5).

30. Lower the vehicle.

31. Vehicles with single A/C system, proceed to step 35. Vehicle with dual A/C system, proceed to next step.

32. Disconnect the fuel line quick connect at the fuel rail.

33. Remove and discard the suction line.

CAUTION:
NOTE THE SUCTION HOSE ROUTING TO THE REAR A/C UNIT BEFORE REMOVING THE SUCTION LINE.

34. Place the new suction line into position.

35. Inspect the receiver/drier previously removed as follows.





36. Using a tape measure, measure down from the top (port side) of the receiver/drier 120.6 mm (4.75 in.) and mark the receiver/drier as shown in (Fig. 6).

37. Using a hacksaw, cut the outside circumference of the receiver/drier case.





38. Inspect inside the receiver/drier for the presence of desiccant powder. Desiccant in this section of the receiver/drier is an indication that desiccant has been released into the A/C system (Fig. 7).

39. If desiccant has been released into the A/C system, continue with Section B - "Removing Desiccant Contamination from the A/C System". If desiccant has not been released into the A/C system, continue with Section C - "Compressor Installation".