LINE-A/C SUCTION
DESCRIPTION
The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line (5).
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.
The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid/suction line assembly is removed.
The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged.
REMOVAL
WARNING: Review safety precautions and warnings in this group before performing this procedure (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal injury or death.
NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C compressor.
NOTE: LHD model shown in illustrations. RHD model similar.
Upper A/C Suction Line
NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line.
NOTE: Illustration shown with front fascia removed for clarity.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
3. Raise and support the vehicle.
4. Remove the A/C accumulator (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR-A/C - REMOVAL).
5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2).
6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket.
7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports.
8. Lower the vehicle.
9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield.
NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid reservoir out of the way. Draining of the coolant and brake fluid is not required when servicing the washer bottle.
10. Remove the windshield washer reservoir (refer to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER RESERVOIR - REMOVAL).
11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5).
12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way.
13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6).
14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.
15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
16. Remove the A/C liquid and suction line assembly from the engine compartment.
Lower A/C Suction Line
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
3. Raise and support the vehicle.
4. Remove the right front wheel (refer to 22 - TIRES/WHEELS - REMOVAL).
5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator (refer to 23 - BODY/EXTERIOR/SPLASH SHIELD-FRONT WHEELHOUSE - REMOVAL).
6. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1).
7. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the O-ring seal and gasket.
8. Install plugs in, or tape over the opened suction line fitting and the accumulator port.
9. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3).
10. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket.
11. Install plugs in, or tape over the opened suction line fitting and the compressor port.
12. Remove the lower A/C suction line from the engine compartment.
INSTALLATION
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). 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 (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
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: LHD model shown in illustrations. RHD model similar.
Upper A/C Suction Line
1. Position the A/C liquid and suction line assembly (4) into the engine compartment.
2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 N·m (105 in. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel.
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 N·m (40 in. lbs.).
8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir (refer to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER RESERVOIR - INSTALLATION).
9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N·m (10 in. lbs.).
NOTE: Illustration shown with front fascia removed for clarity.
11. Raise and support the vehicle.
12. Remove the tape or plugs from the liquid line fitting and the condenser port.
13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is 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.
14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 N·m (44 in. lbs.).
15. Install the A/C accumulator (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR - INSTALLATION).
16. Lower the vehicle.
17. Reconnect the negative battery cable.
18. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE)
19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
20. Charge the A/C system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
Lower A/C Suction Line
1. Position the lower A/C suction line (2) into the engine compartment.
2. Remove the tape or plugs from the suction line fitting and the compressor port.
3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is 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.
4. Connect the lower A/C suction line to the A/C compressor (3).
5. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 N·m (15 ft. lbs.).
6. Remove the tape or plugs from the suction line fitting and the accumulator port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is 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.
8. Connect the lower A/C suction line (3) to the A/C accumulator (1).
9. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the nut to 5 N·m (44 in. lbs.).
10. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely (refer to 23 - BODY/EXTERIOR/SPLASH SHIELD-FRONT WHEELHOUSE - INSTALLATION).
11. Install the right front wheel (refer to 22 - TIRES/WHEELS - INSTALLATION).
12. Lower the vehicle.
13. Reconnect the negative battery cable.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
14. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
15. Adjust the refrigerant oil level (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
16. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).