Installation
INSTALLATION
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 is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.
NOTE: The A/C liquid line is serviced in three sections.
FRONT SECTION
1. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. 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.
3. Position the front section of the A/C liquid line (5) into the engine compartment.
4. Raise and support the vehicle.
5. Connect the front section of the A/C liquid line to the middle section of the A/C liquid line (4).
6. Install the bolt that secures the front section of the A/C liquid line to the middle section of the A/C liquid line. Tighten the bolt to 8 Nm (70 in. lbs.).
7. Install the two nuts that secure the A/C liquid line to the left frame rail. Tighten the nuts to 4 Nm (35 in. lbs.).
8. If equipped with rear A/C, install the A/C underbody lines.
9. Depending on engine application, install the heat shield to the left frame rail.
10. Lower the vehicle.
11. Connect the A/C liquid line to the A/C condenser (7).
12. Install the nut that secures the A/C liquid line to the A/C condenser. Tighten the nut to 6 Nm (53 in. lbs.).
13. Connect the A/C discharge line (8) to the A/C condenser.
14. Install the nut that secures the A/C discharge line to the A/C condenser. Tighten the nut to 6 Nm (53 in. lbs.).
15. Reconnect the negative battery cable.
16. Evacuate the refrigerant system.
17. Adjust the refrigerant oil level.
18. Charge the refrigerant system.
19. Install the air cleaner housing.
MIDDLE SECTION
20. Remove the tape or plugs from the opened refrigerant line fittings.
21. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. 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.
22. Position the middle section of the A/C liquid line (4) into the engine compartment.
23. Connect the middle section of the A/C liquid line to the rear section of the A/C liquid line (3).
24. Install the bolt that secures the middle section of the A/C liquid line to the rear section of the A/C liquid line. Tighten the bolt to 8 Nm (70 in. lbs.).
25. Connect the middle section of the A/C liquid line to the front section of the A/C liquid line (5).
26. Install the bolt that secures the middle section of the A/C liquid line to the front section of the A/C liquid line. Tighten the bolt to 8 Nm (70 in. lbs.).
27. Install the two nuts that secure the A/C liquid line to the left frame rail. Tighten the nuts to 4 Nm (35 in. lbs.).
28. If equipped with rear A/C, install the A/C underbody lines.
29. Depending on engine application, install the heat shield to the left frame rail.
30. Lower the vehicle.
31. Reconnect the negative battery cable.
32. Evacuate the refrigerant system.
33. Adjust the refrigerant oil level.
34. Charge the refrigerant system.
35. Install the air cleaner housing.
REAR SECTION
NOTE: The rear section of the A/C liquid line and A/C suction line are serviced as an assembly.
36. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve ports.
37. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. 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.
38. Position the rear section of the A/C liquid line (3) and the rear section of the A/C suction line (2) into the engine compartment as an assembly.
39. Raise and support the vehicle.
40. Connect the rear section of the A/C suction line to the middle section of the A/C suction line (11).
41. Connect the rear section of the A/C liquid line to the middle section of the A/C liquid line (4).
42. Install the bolt that secures the rear section of the A/C liquid line to the middle section of the A/C liquid line. Tighten the bolt to 8 Nm (70 in. lbs.).
43. If equipped with rear A/C, install the A/C underbody lines.
44. Depending on engine application, install the heat shield to the left frame rail.
45. Lower the vehicle.
46. Install the bolt that secures the rear section of the A/C suction line to the middle section of the A/C suction line. Tighten the bolt to 8 Nm (70 in. lbs.).
47. Install the rear section of the A/C liquid and suction lines onto the A/C expansion valve (1).
48. Install the nut that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the nut to 6 Nm (53 in. lbs.).
49. Install the two nuts that secure the rear section of the A/C liquid line and the rear section of the A/C suction line to the dash panel. Tighten the nuts to 4 Nm (35 in. lbs.).
50. On diesel engine equipped models, position the wire harness and bracket to the air cleaner housing bracket located on the dash panel at the rear of the engine compartment and install the two retaining nuts. Tighten the nuts securely.
51. Reconnect the negative battery cable.
52. Evacuate the refrigerant system.
53. Adjust the refrigerant oil level.
54. Charge the refrigerant system.
55. Install the air cleaner housing.