Repair Procedure B

Removing Desiccant Contamination from the A/C System.

NOTE:
0-RING PACKAGE **05135005AA** IS REQUIRED TO RESEAL THE EXPANSION VALVE(S).

1. Vehicles with dual A/C system, proceed to step 3. Vehicle with single A/C system, proceed to next step.

2. Disconnect the suction and liquid line from the expansion valve.





3. Remove the two expansion valve retaining screws and remove the expansion valve from the evaporator tube tapping plate (Fig. 8).

4. Disconnect the expansion valve electrical connector (Fig. 8).

5. Using needle nose pliers, remove the refrigerant diverter located in the liquid line port of the evaporator.

6. Using clean compressed air, back flush the evaporator by blowing air into the suction port of the evaporator.

7. Install the refrigerant diverter into the liquid line port of the evaporator.

8. Using clean compressed air, blow out any desiccant from the expansion valve.

9. Install new 0-rings, from 0-ring package (p/n **05135005AA**), onto the evaporator fittings by the tapping plate.

10. Connect the electrical connector to the expansion valve and place the expansion valve onto the evaporator tapping plate fitting. Install the retaining screws and tighten the screws to 11 Nm (97 in. lbs.).

11. RS vehicles proceed to next step. RG vehicles, cover the compressor end of the discharge line with a clean shop towel. Using clean compressed air, blow into the receiver/drier end of the discharge line, through the condenser, catching any contamination at the compressor end of the discharge line.

12. Vehicles with dual A/C system, proceed to step 14. Vehicle with single A/C system, replace the 0-ring on the liquid line and suction line and install the lines to the expansion valve. Tighten the retaining nut to 23 Nm (17 ft. lbs.).

13. Vehicles with single A/C system, proceed to Repair Procedure C - Compressor Installation.

14. Remove the rear seat from the vehicle.

15. Remove the upper and lower scuff panels on the rear lift gate opening.

16. Remove the right side sliding door sill plate.

17. Remove the right rear "D" pillar trim panel.

18. Remove the interior right side quarter trim panel to gain access to the rear heater-A/C unit.

19. Remove the upper and lower air ducts from the rear heater-A/C unit housing.





20. Remove the rear heater-A/C unit housing mounting bolts and strap (Fig. 9).

21. Raise the vehicle on the hoist.





22. Remove the rear heater-A/C unit housing floor mounting nuts from the mounting studs (Fig. 9) and (Fig. 10).

23. Remove the liquid and suction lines from the rear heater A/C unit housing tapping plate located under the vehicle.

CAUTION:
CLEAN THE AREA OF ANY MUD OR DIRT TO PREVENT DEBRIS FROM FALLING INTO THE A/C LINES.

24. Lower the vehicle.

25. Using clamp-off pliers, clamp-off the two heater hoses at the rear heater-A/C unit housing and disconnect the heater hoses from the rear heater core.

NOTE:
PLACE A SHOP TOWEL UNDER THE HEATER HOSE CONNECTIONS TO CATCH ANY COOLANT THAT MIGHT SPILL.

26. Disconnect the electrical connections on the rear heater-A/C unit housing.

27. Remove the rear heater-A/C unit from the vehicle.





28. Remove the liquid and suction line access panel retaining screw and then remove the panel (Fig. 11)

29. Remove and save the insulating wrap from the expansion valve.

30. Remove the suction/liquid line retaining nut and bracket at the expansion valve and remove the lines.





31. Remove the two (2) expansion valve mounting screws and remove the expansion valve from the evaporator tube tapping plate (Fig. 12).

32. Using clean compressed air, clean the expansion valve by blowing out any desiccant from the expansion valve, evaporator and the suction and liquid lines.

33. Install new 0-rings onto the evaporator fittings and install the expansion valve onto the evaporator fittings. Tighten the retaining screws to 11 Nm (97 in. lbs.) (Fig. 12).

34. Install new 0-rings on the suction line and liquid line.

35. Install the suction line, liquid line and the retaining bracket and nut. Tighten the retaining nut to 23 Nm (17 ft. lbs.).

36. Install the liquid and suction line access panel into position and insert the retaining screw. Tighten the screw to 2 Nm (18 in. lbs.).

37. Install the insulating wrap onto the expansion valve.

38. Install the rear heater-A/C unit housing into position and install retaining strap and mounting bolts.

39. Connect the heater hoses and remove the clamp-off pliers.

40. Connect the electrical connectors to the rear heater-A/C unit housing.

41. Install upper and lower air ducts.

42. Install the quarter trim panel.

43. Install the "D" pillar trim panel.

44. Install the upper and lower lift gate opening scuff panels.

45. Install the right side sliding door sill plate.

46. Install the rear seat.

47. Lift the vehicle on the hoist and install the housing mounting nuts (Fig. 10).

48. Using clean compressed air, blow out the liquid and suction lines at the rear heater-A/C unit housing.

NOTE:
THE FORWARD END OF THE LIQUID LINE MUST BE POINTED AWAY FROM THE FRONT EXPANSION VALVE BEFORE BLOWING OUT THE LIQUID LINE. THIS WILL KEEP CONTAMINATION FROM BEING BLOWN AT THE FRONT EXPANSION VALVE.

49. Install new 0-rings on the liquid and suction lines.

50. Connect the liquid and suction lines to the rear heater-A/C unit housing tapping plate.

51. Continue with Section C - "Compressor Installation."