Removal

5.9L/6.7L DIESEL ENGINES

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

NOTE: The A/C liquid line is serviced in two sections.

FRONT SECTION




1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system.

3. Remove the passenger side battery.

4. Remove the air seal from the right end of the A/C condenser (5) to gain access to the refrigerant line fittings.

5. Remove the nut (2) that secures the front section of the A/C liquid line (1) to the A/C condenser (3).

6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and gasket.




7. Disengage the A/C liquid line (1) from the three body retaining clips (2 and 3) located at the right front corner of the engine compartment.




8. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (1) to the rear section of the liquid line (3).

9. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals.

10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser port.

11. Remove the front section of the A/C liquid line from the engine compartment.

REAR SECTION




12. Disconnect and isolate the negative battery cable.

13. Recover the refrigerant from the refrigerant system.

14. Remove the passenger side battery.

15. Disengage the rear section of the A/C liquid line (2) from the body retaining clip (5).

16. Remove the secondary retaining clip (1) from the spring-lock coupler that secures the front section of the A/C liquid line (6) to the rear section of the A/C liquid line.

17. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals.

18. Remove the secondary retaining clip (3) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator tube (4).

19. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C liquid line from the evaporator tube and remove and discard the O-ring seals.

20. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator tube,

21. Remove the rear section of the A/C liquid line from the engine compartment.