Auxiliary Evaporator Outlet and Inlet Line

AUXILIARY EVAPORATOR OUTLET AND INLET LINE

Part 1:

Part 2:

Removal and Installation

CAUTION: It is necessary to cut the underbody auxiliary line(s) being serviced into sections to facilitate removal. Make sure to correctly identify the line(s) being serviced before carrying out any cutting of the line(s).

NOTE:
- The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing 2-piece lines for ease of installation.
- The following procedure can be used to remove and install one or both of the auxiliary evaporator inlet line and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.

All vehicles
1. Recover the refrigerant.
2. Remove the muffler.

AWD vehicles
3. Remove the rear driveshaft.

All vehicles
4. Remove the exhaust heat shield.
5. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).

6. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).

7. Remove the LH rear wheel.
8. Remove the LH rear quarter panel moulding.
9. Remove the 3 outer LH rear quarter panel moulding bracket bolts and the LH rear quarter panel moulding bracket.
10. Remove the 2 inner LH rear quarter panel moulding bracket bolts.
11. Remove the LH rear quarter panel moulding bracket.
12. Remove the 2 LH rear brake caliper bolts and position the caliper aside.
- To install, tighten to 35 Nm (26 lb-ft).

13. Remove the 2 parking brake cable bolts.
- To install, tighten to 12 Nm (9 lb-ft).

AWD vehicles
14. Remove the 4 rear subframe bracket bolts.
- To install, tighten to 63 Nm (46 lb-ft).

15. Remove the lower control arm bolt.
- To install, tighten to 90 Nm (66 lb-ft).

All vehicles

16. NOTE: AWD vehicle shown, FWD vehicle similar.

Remove the LH lower shock bolt.
- To install, tighten to 142 Nm (105 lb-ft).

17. Position a lifting table to support the rear subframe.
18. Remove the 2 LH rear subframe bolts and lower the subframe.
- To install, tighten to 115 Nm (85 lb-ft).

19. Correctly support the fuel tank and remove the LH rear fuel tank strap bolt.
- To install, tighten to 35 Nm (26 lb-ft).

20. Remove the rear auxiliary inlet line fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).

21. Remove the rear auxiliary outlet line fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).

22. Remove the 2 middle rear auxiliary line bracket bolts.
- To install, tighten to 5 Nm (44 lb-in).

23. Remove the 2 middle rear auxiliary line brackets.
24. Remove the 2 middle front auxiliary line bracket nuts.
- To install, tighten to 5 Nm (44 lb-in).

25. Remove the 2 middle front auxiliary line brackets.

26. CAUTION: To avoid loss of coolant, or unintended damage to an auxiliary line that is not being removed, clearly differentiate which line is to be removed before cutting.

Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the middle fitting on the replacement line(s).
- To install, connect the middle auxiliary evaporator line fitting(s).

27. Remove the front auxiliary line bracket nut.
- To install, tighten to 5 Nm (44 lb-in).

28. Remove the front auxiliary line bracket.
29. Remove the front portion of the auxiliary evaporator outlet line and/or auxiliary evaporator inlet line.
30. Remove the rear auxiliary line bracket nut.
- To install, tighten to 5 Nm (44 lb-in).

31. Remove the rear auxiliary line bracket.
32. Remove the rear portion of the auxiliary evaporator outlet line and/or the auxiliary evaporator inlet line.
33. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.

34. Evacuate, leak test and charge the refrigerant system.