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 these instructions 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.

NOTE: The underbody heater and A/C refrigerant lines can each be serviced individually. However, all underbody lines will need to be removed as an assembly from the vehicle and then separated from each other on a workbench.





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.
5. Remove the rear section of the exhaust system Exhaust Pipe - Removal.
6. Remove the exhaust heat shields as necessary to gain access to the underbody lines Heat Shield - Description.

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

7. Release the spring type hose clamps (2), disconnect the front heater hoses (1) from the underbody heater lines (4) and disengage the underbody heater lines from the underbody line bracket (3).
8. Loosen the fitting nuts (6 and 7) that secure the underbody refrigerant lines (5) to the A/C underbody extension lines (8), disconnect the A/C underbody lines from the extension lines and remove and discard the O-ring seals.





9. Remove the two nuts (3) and one screw (1) that secure the underbody line shield (2) to the vehicle underbody and remove the shield.






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

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

10. Release the spring type hose clamps (3), disconnect the underbody heater lines (4) from the rear heater core tubes and lower the underbody heater lines to drain any residual coolant from the lines.

CAUTION: Use care when disconnecting the refrigerant lines and sealing plate from the rear A/C expansion valve. DO NOT to hit the heater hose below. Contact with the heater hoses may result in damage to the rubber heater hose ends and replacement of the heater hose ends will then be required.

11. Remove the nut (2) that secures the underbody refrigerant lines (1 and 5) and sealing plate to the rear A/C expansion valve, disconnect the underbody lines from the expansion valve and remove and discard the O-ring seals.





12. Disconnect the rear ABS wire harness lead and bracket (4) from the right side of the body (3) to gain clearance to partially lower the right side of the rear cradle.

NOTE: It is not necessary to disconnect the brake line to remove it from the brackets.

13. Remove the two bolts (6) that secure the right rear brake line (1) to the two brackets (2 and 5) and remove the brake line from the brackets to gain clearance to partially lower the right side of the rear cradle.






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

14. Remove the lower right rear shock retaining bolt . Rear Shock Absorber, Coil-Over - Removal

WARNING: Be sure to properly support the rear cradle before removing the right side retaining bolts. Failure to follow this warning may result in serious or fatal injury.

15. Support the right side of the rear cradle with a suitable jack stand and remove the bolts that secure the right side of the cradle to the body Crossmember - Removal.

CAUTION: Use care not to damage the ABS wire lead or the brake line when lowering the rear cradle for clearance.

16. Carefully lower the jack stand until the right side of the rear cradle (supported by the stand) is approximately 76-101 mm (3-4 in.) below the body. This will allow access to remove the underbody lines.
17. Remove the nut (5) that secures the underbody line bracket (4) to the stud located near the center of the underbody (6).
18. Disengage the remainder of the underbody line brackets (1, 2, and 7) from the studs located underneath the vehicle.
19. Rotate and tilt the underbody lines (3) as necessary and remove the lines as an assembly from under the vehicle.
20. Install plugs in, or tape over, all the opened refrigerant line fittings and the rear expansion valve ports.





21. If replacement of one or more of the underbody lines is required, place the underbody line assembly on a workbench, disengage the underbody line brackets and separate the lines as necessary.
22. If servicing the A/C liquid line (2) or A/C suction line (3), disengage the nylon retaining clip (4) that secures the suction line to the liquid line sealing plate (1) and separate the refrigerant lines from each other.