REFRIGERANT LINE (LO PRESSURE SIDE) REMOVAL/INSTALLATION [AJ (3.0L Duratec), YF (2.0L Zetec)]

Note

• When removing/installing the refrigerant line, refer to removal/installation note. (See Refrigerant Line Removal Note.) (See Refrigerant Line Installation Note.)

L.H.D.

1. Discharge the refrigerant from the system. (See DISCHARGING AND RECOVERY.)

2. Remove the nuts from the refrigerant line mounting bracket.

3. Disconnect the refrigerant line from the accumulator tank.

Caution

• Plug all ports to prevent contamination from dirt or moisture.

4. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION.)

5. Remove the nut and disconnect the refrigerant line to condenser fitting.

6. Raise and support the vehicle.

7. Remove the RH splash shield.

8. If equipped, disconnect the engine block heater connector.

9. Disconnect the magnetic clutch connector.

10. Remove the refrigerant line installation bolt from the top of the A/C compressor and disconnect the refrigerant line.

Caution

• Plug all ports to prevent contamination from dirt or moisture.

Note

• Vehicle with YF (2.0L Zetec) engine shown, vehicle with the AJ (3.0L Duratec) engine similar.

11. Remove the refrigerant line (LO pressure side) through the bottom of the vehicle.

12. Install in the reverse order of removal.

(1) Lubricate the new O-ring with PAG Compressor Oil.

(2) Apply Pipe Sealant.

R.H.D.

1. Discharge the refrigerant from the system. (See DISCHARGING AND RECOVERY.)

2. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION.)

3. Remove the nut and disconnect the refrigerant line to condenser fitting.

4. Remove the nuts from the refrigerant line mounting bracket.

5. Disconnect the refrigerant line.

(1) Remove the nut from the refrigerant line fitting.

(2) Disconnect the refrigerant line and tube pin-type retainer.

6. Disconnect the refrigerant line.

Caution

• Plug all ports to prevent contamination from dirt or moisture.

• Use a wrench on each side of the fitting to prevent damage to A/C fitting.

7. Remove the nut and refrigerant line.

8. Raise and support the vehicle.

9. Remove the RH splash shield.

10. If equipped, disconnect the engine block heater connector.

11. Disconnect the magnetic clutch connector.

12. Remove the refrigerant line installation bolt from the top of the A/C compressor and disconnect the refrigerant line.

Caution

• Plug all ports to prevent contamination from dirt or moisture.

Note

• Vehicle with YF (2.0L Zetec) engine shown, vehicle with the AJ (3.0L Duratec) engine similar.

13. Remove the refrigerant line (LO pressure side) through the bottom of the vehicle.

14. Install in the reverse order of removal.

(1) Lubricate the new O-ring with PAG Compressor Oil.

(2) Apply Pipe Sealant.

Refrigerant Line Removal Note

Nut joint type

1. Loosen the nut using two spanners, then remove the refrigerant line.

Block joint type

1. Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then remove the connection bolt or nut.

Spring-lock coupling type

1. Set the SST.

2. While looking through the inspection hole of the SST, insert the protruding part of the SST until it makes contact with the cage section.

3. Use the SST to disconnect the male pipe or hose from the female by pulling the male pipe or hose.

Note

• The male pipe or hose can be disconnected easily from the female pipe by pulling from the male pipe or hose while maintaining the pressure of the protruding part of the SST.

Refrigerant Line Installation Note

1. Apply compressor oil to the O-ring joints.

2. Tighten the joints.

Nut or block joint type

1. Tighten the nut or bolt of joint by hand.

2. Tighten the joint to specified torque. If it is a nut joint, tighten the nut with spanner and torque wrench.

3. Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and holding firmly, then tighten the connection bolt or nut with a torque wrench.

Spring-lock coupling

1. Connect the male pipe or hose by twisting it onto female pipe until the garter spring at the male pipe or hose is over the flared end of female pipe.

Note

• When the male pipe or hose is replaced, the indicator ring comes out after connecting to indicate that it is locked.