A/C Suction Hose/Line Replacement

REMOVAL

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT BEFORE PERFORMING THE FOLLOWING OPERATION.

1. Recover the refrigerant from the refrigerant system.
2. Remove the bolt that secures the suction line fitting to the top of the compressor.
3. Disconnect the suction line fitting from the compressor inlet port.
4. Remove the O-ring seal from the suction line fitting and discard.
5. Install plugs in, or tape over the opened suction line fitting and the compressor inlet port.

Suction Line - 2.4L LHD Shown, RHD Typical:

6. Disconnect the front suction line from the mid-line connector block of the rear suction line assembly.
7. Remove the O-ring seal from the suction line fitting and discard.
8. Install plugs in, or tape over the opened suction line fitting and the mid-line connector block.
9. Remove the suction line from the retaining brackets as required and remove the front suction line from the engine compartment.
10. If equipped, relocate the vehicle speed control servo as necessary to access the receiver/drier.
11. Remove the bolt that secures the rear section of the liquid line to the receiver/drier outlet port.
12. Remove the O-ring seals from the opened liquid line fitting and discard.
13. Install plugs in, or tape over the opened liquid line fitting and receiver/drier outlet port.
14. Remove the bolt that secures the rear suction and liquid line assembly to the A/C expansion valve.
15. Disconnect the rear suction and liquid line assembly from the A/C expansion valve
16. Remove the gasket from the A/C expansion valve and discard.
17. Install plugs in, or tape over the opened rear suction and liquid line fittings and both expansion valve ports.
18. Disengage the rear suction and liquid line assembly from the retaining clips as required and remove the rear suction and liquid line assembly from the engine compartment.

INSTALLATION
1. Position the rear suction and liquid line assembly into the engine compartment.
2. Engage the rear suction and liquid line assembly to the retaining clips as required.
3. Remove the tape or plugs from the liquid and suction line fittings and both ports on the front of the A/C expansion valve.
4. Install a new gasket onto the A/C expansion valve.
5. Connect the liquid and suction line fitting to the A/C expansion valve.
6. Install the bolt that secures the suction and liquid line fitting to the A/C expansion valve. Tighten the bolt to 20 Nm (15 ft. lbs.).
7. Position the front suction line into the engine compartment.
8. Remove the tape or plugs from the front suction line fitting and the mid-line connector block.
9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 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 compressor in the vehicle.
10. Connect the front suction line fitting to the mid-line connector block.
11. Install the nut that secures the front suction line fitting to the mid-line connector block. Tighten the nut to 4.5 Nm (40 in. lbs.).
12. Remove the tape or plugs from the opened liquid line fitting and receiver/drier outlet port.
13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. 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 compressor in the vehicle.
14. Reconnect the liquid line fitting to the receiver/drier outlet port.
15. Install the bolt that secures the liquid line fitting to the receiver/drier. Tighten the bolt to 2.3 Nm (20 in. lbs.).
16. If equipped, reinstall the vehicle speed control servo.
17. Remove the tape or plugs from the A/C compressor suction port and the suction line fitting.
18. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 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.
19. Connect the suction line fitting to the A/C compressor suction port.
20. Install the bolt that secures the suction line fitting to the A/C compressor. Tighten the bolt to 12 Nm (108 in. lbs.).
21. Install the suction line retaining brackets as required.
22. Evacuate the refrigerant system.
23. Recharge the refrigerant system.