Repair Procedure

1. Recover the refrigerant in the A/C system.

CAUTION:
WEAR PROTECTIVE GLASSES AT ALL TIMES. ANY TIME THE AIR CONDITIONING SYSTEM IS OPENED THERE MAY BE REMAINING PRESSURE THAT ALLOWS THE A/C SYSTEM OIL TO SQUIRT OUT.

NOTE:
IT IS NOT NECESSARY TO REMOVE THE UPPER TORQUE STRUT FROM THE ENGINE TO PERFORM STEP TWO. THE UNIFIED A/C LINE CAN BE REMOVED WITH THE UPPER TORQUE STRUT IN PLACE.

2. Remove and discard the A/C unified line by removing the bolt at the filter drier bottle, the bolt at the dash panel and the bolt at the suction port of the compressor. Do not remove the filter/drier bottle and liquid line. Do not leave the filter/drier bottle exposed to air for any length of time to prevent moisture contamination.

3. Place a rag over the power steering belt to catch oil drips.









4. Install the new A/C suction line (p/n 05278761AB) and A/C unified line (p/n 05015344AC). The new suction line will use the alternate A/C compressor bolt hole. Torque the bolt at the dash panel to 22.5 Nm (200 in.lbs). Torque the nut/stud to 11.8 Nm (105 in.lbs). Torque the filter drier bolt to 11.2 Nm (100 in.lbs). Torque the A/C compressor bolt to 12.2 Nm (108 in.lbs). (Figures 1 and 2).

5. Evacuate the A/C system.

6. Siphon enough coolant through the coolant cap to allow removal of the upper radiator hose.





7. Install the radiator hose sleeve (05017627AA) by sliding the braided sleeve over the hose. Secure the hose with the three rubber bands provided (Figure 3).





8. Install the accelerator cable clip over the center rubber band (Figure 4).





9. Install the fan shroud clip (p/n 05278762AA) with the existing left side cooling fan shroud mounting bolt and torque to 7.3 Nm (65 in.lbs) (Figure 5).

10. Position the crossmember clip to the top side of the radiator crossmember and mark with a scribe.





NOTE:
ENSURE THAT THE PILOT HOLE IS POSITIONED SO THAT THE CLIP DOES NOT CONTACT THE POWER STEERING RESERVOIR (FIGURE 6). ALSO ENSURE THAT THE ALUMINUM TUBING DOES NOT CONTACT THE SHEET METAL OR A BUZZ MAY OCCUR.

11. Using the scribe mark made in step 10, drill a 7/32 pilot hole into the radiator crossmember. Install the crossmember clip screw (p/n 06505529AA) and torque to 7.3 Nm (65 in.lbs).

12. Install the new A/C underhood specification label (p/n 05264840AC) over the existing label (Figure 3).

13. Charge the A/C system with a new amount of 1.875 lbs. of refrigerant and ensure all oil recovered by the refrigerant recovery machine is returned to the vehicle. If the A/C system is low on oil an objectionable noise may be heard.