A/C Underbody Lines - Installation

INSTALLATION

CAUTION:
Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. 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, refer to 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 is required anytime an underbody refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.





1. Position the underbody lines (1) underneath the vehicle body and install the six retaining screws (2 and 3). Tighten the screws securely.

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

2. Install the rear brake line bracket, brake line and ABS wire lead onto the rear frame rail.

3. Install the right rear shock mount onto the rear frame rail and remove the jack stand from under the rear axle.

4. Reposition the exhaust system and connect the four rubber exhaust hanger isolators.





5. Connect the front heater hoses (4) to the underbody heater lines (3) and install the hose clamps securely.

6. Remove the tape or plugs from all the opened refrigerant line fittings and the rear expansion valve ports.

7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto all the underbody 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.

8. Connect the front A/C suction line (6) and front A/C liquid line (5) to the underbody refrigerant lines (1 and 2). Tighten the fitting nuts to 23 Nm (17 ft. lbs.).





9. If removed, install the suction extension line (3) into the sealing plate (1) and install the nylon retaining clip (4) that secures the suction line to the sealing plate.





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

10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant extension 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.

11. Connect the underbody refrigerant extension lines (3) and the sealing plate (4) to the rear A/C expansion valve (1).

12. Loosely install the nut (2) that secures the extension lines and sealing plate to the rear A/C expansion valve.

13. Connect the underbody refrigerant lines to the underbody refrigerant extension lines and tighten the fitting nuts to 23 Nm (17 ft. lbs.).

14. Tighten the nut that secures the extension lines and sealing plate to the rear A/C expansion valve to 11 Nm (95 in. lbs.).





15. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the rear heater core tube fittings. Use only the specified O-rings as they are made of a special material designed for use with engine coolant. Use only engine coolant of the type recommended for the engine in the vehicle.

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

16. Connect the quick connect fittings (3) for the underbody heater lines (4) to the rear heater core tubes (1) and engage the inserts (2). Make sure the inserts are fully engaged to the rear heater core tube fittings.

17. Lower the vehicle.

18. Reconnect the negative battery cable.

19. Fill the engine cooling system Service and Repair.

20. Evacuate the refrigerant system Refrigerant System Evacuate.

21. Adjust the refrigerant oil level Refrigerant Oil Level.

22. Charge the refrigerant system Refrigerant System Charge.