Discharge Hose Replacement (6.0L Engine)

Discharge Hose Replacement (6.0L Engine)

Tools Required

J 39400-A Halogen Leak Tester


Removal Procedure

Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
3. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
4. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair)
5. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair) .




6. Remove the discharge hose retaining bracket to oil pan retaining bolt (1).
7. Position the discharge hose retaining bracket (2) away from the oil pan (3).




8. Remove the suction pipe upper to suction pipe lower retaining nut (1).




9. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Important: The sealing washer (3) is a single use item and must be discarded after use.


10. Remove the sealing washer (3). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.


11. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).




12. Remove the suction/discharge pipe to compressor retaining bolt (2).




13. Disconnect the suction/discharge pipes (1) from the compressor (3).

Important: The sealing washers (2) are a single use item and must be discarded after use.


14. Remove the sealing washers (2). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
Discard the sealing washers.

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.


15. Cap or plug the suction/discharge pipes (1) and the ports on the compressor (3).





Important: Remove the upper radiator support brackets by raising the securing lock upwards 10mm and slide the bracket of the radiator slide pin.


16. Remove the upper radiator support brackets (1).





Important: Gently push the radiator and condenser towards the engine to allow removal of the discharge pipe to condenser retaining nut (1).


17. Remove the discharge pipe to condenser retaining nut (1).




18. Disconnect the discharge pipe (1) from condenser (3).
19. Remove the sealing washer (2). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
Discard the sealing washer.

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.


20. Cap or plug the discharge pipe (1) and the condenser (3).



Installation Procedure





1. Remove the plugs or caps from the discharge pipe (1) and the condenser (3).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.


2. Install a NEW sealing washer (2). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
3. Install the discharge pipe (1) to condenser (3).





Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Gently push the radiator and condenser towards the engine to allow installation of the discharge pipe to condenser retaining nut (1).


4. Install the discharge pipe to condenser retaining nut (1).

Tighten the nut to 22 N.m (16 lb ft).





5. Install the upper radiator support brackets (1).




6. Remove the plugs or caps from the suction/discharge pipes (1) and the ports on the compressor (3).

Important: DO NOT coat the sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the washer useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.


7. Install two NEW sealing washers (2). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
8. Connect the suction/discharge pipes (1) to the compressor (3).




9. Install the suction/discharge pipe to the compressor retaining bolt (2).

Tighten the bolt to 22 N.m(16 lb ft).





10. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.


11. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
12. Install the suction pipe upper (1) to the suction pipe lower (2).




13. Install the suction pipe upper to suction pipe lower retaining nut (1).

Tighten the nut to 22 N.m(16 lb ft).





14. Position the discharge hose retaining bracket (2) to the oil pan (3).
15. Install the discharge hose retaining bracket to oil pan retaining nut (1).

Tighten the nut to 22 N.m (16 lb ft).

16. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair)
17. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair) .
18. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
21. Leak test the fittings of the components using J 39400-A .