Installation

5.9L/6.7L DIESEL ENGINES

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.

NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line.




1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3).

2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports.

3. Position the A/C suction and discharge line assembly into the engine compartment.

4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are 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.

5. Connect the A/C suction and discharge line assembly to the A/C condenser (1).

6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.).

7. Connect the A/C suction and discharge line assembly to the A/C compressor (6).

8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.).

9. Connect the wire harness connector (5) to the A/C pressure transducer.




10. Remove the tape or plugs from the opened accumulator tube.

11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are 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.

12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7).

13. Install the air filter housing cover.

14. Reconnect the negative battery cables.

15. Evacuate the refrigerant system.

16. Adjust the refrigerant oil level.

17. Charge the refrigerant system.