A/C Suction Line - Installation
INSTALLATION
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Level . 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, see 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 and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.
NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.
NOTE: LHD model shown in illustrations. RHD model similar.
FRONT SUCTION LINE
1. Remove the tape or plugs from the suction line fittings and compressor port.
2. Lubricate a new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction line fittings. Use only the specified O-ring 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.
3. Position the front portion of the A/C suction line (3) into the engine compartment.
4. Connect the front portion of the A/C suction line to the rear portion of the A/C suction line (1) and install the retaining nut (2). Tighten the nut to 5 Nm (44 in. lbs.).
5. On diesel engine models;
a. reposition the right front wheel house splash shield to the body Splash Shield - Installation.
b. install the right front wheel Tires and Wheels - Installation.
c. Lower the vehicle.
6. Connect the A/C suction line (2) to the A/C compressor (3).
7. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.).
8. On gasoline engine models;
a. install the drive belt splash shield.
b. reposition the right front wheel house splash shield to the body Splash Shield - Installation.
c. install the right front wheel Tires and Wheels - Installation.
d. Lower the vehicle.
9. On diesel engine models, install the right front impact sensor onto the radiator support Front.
10. Reconnect the negative battery cable.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
11. Evacuate the refrigerant system Refrigerant System Evacuate.
12. Adjust the refrigerant oil level Refrigerant Oil Level.
13. Charge the A/C system Refrigerant System Charge.
SUCTION AND LIQUID LINE ASSEMBLY
NOTE: The rear portion of the A/C suction line is serviced as an assembly with the A/C liquid line.
1. Position the A/C suction and liquid line assembly (4) into the engine compartment.
2. Remove the tape or plugs from the refrigerant line fittings and the expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the liquid and suction line fittings. Use only the specified O-ring seals as they are made of special materials compatible to 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 suction and liquid line assembly to the A/C expansion valve (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C expansion valve. Tighten the bolt to 20 Nm (15 ft. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel.
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.).
8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant reservoir.
9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.).
11. On all models, raise and support the vehicle.
NOTE: Illustration shown with front fascia removed for clarity.
12. On late model year vehicles equipped with a gasoline engine and four speed automatic transaxle;
a. remove the tape or plugs from the liquid line fitting and the condenser port.
b. lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring 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.
c. connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten the nut to 5 Nm (44 in. lbs.).
13. Remove the tape or plugs from the suction line fittings.
14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fittings. Use only the specified O-ring 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.
15. Connect the front portion of the A/C suction line (4) to the rear portion of the A/C suction line (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.).
16. Install the A/C suction line into the plastic bracket on the A/C receiver/drier (6), or install the suction line retaining bracket to the right front frame rail, depending on engine and transaxle application.
17. On all models, except late model year vehicles equipped with a gasoline engine and four speed automatic transaxle;
a. remove the tape or plugs from the liquid line fitting and the receiver/drier port.
b. lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring 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.
c. connect the A/C liquid line (1) to the A/C receiver/drier (6) and install the retaining nut (5). Tighten the nut to 5 Nm (44 in. lbs.).
18. On all models;
a. reposition the right front wheel house splash shield to the body Splash Shield - Installation.
b. install the right front wheel Tires and Wheels - Installation.
c. Lower the vehicle.
19. Reconnect the negative battery cable.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
20. Evacuate the refrigerant system Refrigerant System Evacuate.
21. Adjust the refrigerant oil level Refrigerant Oil Level.
22. Charge the A/C system Refrigerant System Charge.