A/C Underbody Lines - Removal

REMOVAL

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation Warning and Caution . Failure to follow the warnings and cautions may result in serious or fatal injury.

NOTE: To prevent any contaminates from entering the rear heating-A/C system, make sure that the area around the underbody line connections is clean of any dirt or foreign residue prior to disconnecting the lines.





1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system Refrigerant System Recovery.
3. Drain the engine cooling system Service and Repair.
4. Raise and support the vehicle.

CAUTION: DO NOT apply excessive force on underbody heater lines or rear heater hose quick connect fittings when disconnecting the connections. Excessive force may damage or deform the fittings and or lines, causing an engine coolant leak.

5. Disconnect the underbody heater lines (4) from the rear heater core tubes (1) which extend through the rear floor panel in front of the right rear wheel housing by releasing the insert (2) in each rear quick connect fitting (3) and carefully pulling downward on the fittings while using a slight twisting motion.
6. Lower the underbody heater lines and drain any residual coolant from the lines into a suitable container.






NOTE: Illustration shown with rear body cradle removed for clarity.

7. Loosen the fitting nuts that secure the underbody refrigerant lines to the underbody refrigerant extension lines (3) located behind the right rear wheel housing.
8. Disconnect the underbody refrigerant lines from underbody refrigerant extension lines and remove and discard the O-ring seals.
9. Remove the nut (2) that secures the underbody refrigerant extension lines and sealing plate (4) to the rear A/C expansion valve (1).
10. Disconnect the extension lines from the rear A/C expansion valve and remove and discard the O-ring seals.





11. Loosen the fitting nuts that secure the underbody refrigerant lines (1 and 2) to the front A/C liquid line (5) and the front A/C suction line (6).
12. Disconnect the front A/C liquid and suction lines from the underbody refrigerant lines and remove and discard the O-ring seals.

NOTE: Replacement of the front heater hoses will be required if the hose ends are cut for removal.

13. Release the spring type hose clamps (4) and disconnect the front heater hoses from the underbody heater lines (3).





14. Support the rear axle with a suitable jack stand and remove the right rear shock mount from the rear frame rail and position the mount and shock out of the way.

CAUTION: Use care not to damage the ABS wire lead or the brake line when repositioning the brake line bracket.

15. Remove the rear brake line bracket from the rear frame rail and position the bracket, brake line and ABS wire lead out of the way.
16. Disconnect the exhaust system from the four rubber exhaust hanger isolators and position the exhaust system out of the way.
17. Remove the six screws (2 and 3) that secure the underbody lines (1) underneath the vehicle.
18. Rotate and tilt the underbody lines as necessary and remove the lines from the vehicle.
19. Install plugs in, or tape over all the opened refrigerant line fittings and the rear expansion valve ports.





20. If required, place the extension lines and sealing plate (1) on a workbench, remove the nylon retaining clip (4) that secures the suction extension line (3) to the sealing plate and remove the suction line from the sealing plate.