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.

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





NOTE: Illustration shown with rear axle removed for clarity.

1. Route the underbody line assembly (2) over the rear axle and position the line assembly to the vehicle underbody (3).

2. Engage the five mounting brackets that secure the underbody line assembly to the vehicle underbody.

3. Install the two screws (1) that secure the underbody line assembly to the front of the underbody. Tighten the screws securely.

4. Install the heat shields as required to the vehicle underbody.

5. Install the muffler and tail pipe as an assembly.

6. Install the rear body cradle.





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

7. Remove the tape or plugs from rear underbody refrigerant line fittings and rear expansion valve ports.

8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear 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.

9. Connect the underbody refrigerant lines to the rear A/C expansion valve (3) which extend through the rear floor panel (4) behind the right rear wheel housing.

10. Install the nut (1) that secures the underbody refrigerant lines to the to the rear A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.).

11. Connect the rear heater hoses (6) to the rear heater core tubes (5) and install the heater hose clamps securely.





NOTE: Illustration shown with left front fender liner removed for clarity.

12. Remove the tape or plugs from the opened refrigerant line fittings.

13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install them onto the underbody 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.

14. Connect the liquid line extension tube (2) and the suction line extension tube (3) to the underbody refrigerant lines (6) and install the two nuts (1 and 4). Tighten the nuts to 20 Nm (15 ft. lbs.).

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

16. Lower the vehicle.

17. Reconnect the negative battery cable.

18. Fill the engine cooling system.

19. Evacuate the refrigerant system.

20. Adjust the refrigerant oil level.

21. Charge the refrigerant system.