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.





1. Position the A/C liquid line (1) into the engine compartment.

2. Remove the tape or plugs from the opened liquid and suction line fittings and the receiver/drier and expansion valve ports.

3. Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified seal as it is 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.

4. Connect the A/C liquid line to the A/C expansion valve (2) and engage the two liquid line retainer clips (4) to the frame rail (3).





5. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the front liquid line fitting. Use only the specified seal as it is 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.

6. Connect the A/C liquid line (2) to the A/C receiver/drier (3).

7. Install the nut (1) that secures the A/C liquid line to the A/C receiver/drier. Tighten the nut to 20 Nm (15 ft. lbs.).





NOTE: LHD model with 5.7L engine shown in illustration. RHD model and other engines similar.

8. Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear suction line fitting. Use only the specified seal as it is 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.

9. Connect the A/C suction line (2) to the A/C expansion valve (1).

10. Install the nut (3) that secures the A/C suction line and the A/C liquid line (10) to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.).

11. Install the air cleaner housing, air intake tube and the resonator.

12. Reconnect the negative battery cable.

13. Evacuate the refrigerant system.

14. Adjust the refrigerant oil level.

15. Charge the refrigerant system.