Procedures

UNDERBODY LINE REPAIR

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation Warning and Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury.

WARNING: This procedure is intended for underbody line repair only. Use of the connector fittings and A/C Line Repair Tools 8456A on any other type of vehicle tubing may cause tube failure resulting in possible serious or fatal injury.





1. If repairing an underbody refrigerant line, recover the refrigerant from the refrigerant system . Refrigerant System Recovery
2. If repairing an underbody coolant line, drain the engine cooling system Service and Repair.
3. Disconnect and isolate the negative battery cable.
4. Raise and support the vehicle.
5. Remove the underbody mounting brackets as necessary to gain access to the underbody line(s) needing repair A/C Underbody Lines - Removal.
6. Mark the cut location(s) on the underbody line(s) needing repair. Check the Tube Length chart for the minimum amount of straight tube required (dimension A) for proper connector fitting installation.
7. Using a small pipe cutter or another suitable tool, carefully cut the underbody line(s) needing repair at the location(s) previously marked.

TUBE LENGTH










8. Size a replacement line, same size diameter and length as the portion of the line(s) removed.

NOTE: A minimum of 28.5 mm (3/4 in) of the line end must be cleaned in order for the connector fitting to properly seal the repair area.

9. Clean the ends of the line(s) a minimum of 28.5 mm (3/4 in) (dimension A) using the Scotch-Bright(R) pad provided with A/C Line Repair Tool Kit 8456A. Clean the line end(s) with a rotational motion around the line to avoid longitudinal scratches in the line.





10. Select the proper connector fitting (1) for the size of the underbody line being repaired. See the Connector Fitting chart.
11. Apply one drop of Lokprep(R) sealing compound provided with A/C Line Repair Tool Kit 8456A onto each line end (2).
12. Insert the line ends into the selected connector fitting and rotate the connector fitting a complete turn to evenly distribute the sealing compound.

CONNECTOR FITTING










13. Select the proper size jaws (1) for the line being repaired from the A/C Line Repair Tool Kit 8456A. See the Jaw Size chart.
14. Assemble the jaws into Tool Body 8456-3 (2) (in Kit 8456A).
a. For standard installation, install the jaws with the rubber gripping pads (3) facing outward. See the Tube Length chart.
b. For reversed installation, remove the rubber gripping pads and install the jaws with the rubber gripping pad area facing inward. See the Tube Length chart.

JAW SIZE











NOTE: The connector fitting ends must be positioned into the counterbore of the jaws in order for the connector fitting to properly seal the repair area.

15. Install the connector fitting (1) and the line ends (4) into the counterbore of the jaws (5).
16. Hold Tool Body 8456-3 (2) with a 3/8 inch breaker bar and turn the forcing screw (3) clockwise.






NOTE: The lines must be kept fully inserted into the connector fitting to obtain a leak free joint.

17. Turn the forcing screw (1) clockwise until both connector fitting collars (2) have bottomed out on the center shoulder of the connector (3).
18. Loosen the forcing screw and remove Tool Body 8456-3 (4) and the jaws (5) from the repaired line(s).
19. Install the underbody mounting brackets as necessary A/C Underbody Lines - Installation.
20. Lower the vehicle.
21. Reconnect the negative battery cable.
22. If repairing an underbody coolant line, refill the engine cooling system Service and Repair.
23. If repairing an underbody refrigerant line, evacuate and charge the refrigerant systemRefrigerant System Charge.