A/C Underbody Lines - Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level .

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets may result in a refrigerant system leak.






NOTE: Illustration shown with rear axle and cradle removed for clarity.

1. Route the underbody line assembly (1) over the rear axle and cradle and position the line assembly to the vehicle underbody.
2. Engage the five mounting brackets (2 and 4) to the five studs (3) on the vehicle underbody.
3. Install the previously removed underbody heat shields.





4. Remove the tape or plugs from the opened refrigerant line fittings and rear expansion valve ports.
5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
6. Connect the underbody refrigerant lines (3) to the rear A/C expansion valve (2).
7. Install the nut (1) that secures the underbody refrigerant lines to the to the rear A/C expansion valve. Tighten the nut to 11 Nm (97 in. lbs.).
8. Connect the rear heater hoses (5) to the rear heater core tubes and install the heater hose clamps (4) securely.
9. Install the rear body cradle Crossmember - Installation.
10. Install the right rear shock absorber onto the lower control arm.
11. Install the right rear caliper Disc Brake Caliper - Installation.
12. Install the two right side fuel tank straps Fuel Tank - Installation.
13. Install the muffler, resonator and tail pipe assembly Installation.





14. If servicing the upper A/C suction and liquid lines (4 and 10), install the upper lines onto the bracket (3) and install the two retaining nuts (1 and 2). Tighten the nuts securely.
15. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
16. Connect the underbody refrigerant lines (5 and 9) to the upper A/C suction and liquid lines and install the two retaining nuts (6 and 7). Tighten the nuts to 20 Nm (15 ft. lbs.).
17. Connect the heater hoses to the underbody heater lines (8) and install the heater hose clamps securely.
18. Lower the vehicle.
19. Reconnect the negative battery cable.
20. Fill the engine cooling system Service and Repair.
21. Evacuate the refrigerant system Refrigerant System Evacuate.
22. Adjust the refrigerant oil level as necessary Refrigerant Oil Level.
23. Charge the refrigerant system Refrigerant System Charge.