A/C Liquid Hose/Line Replacement

RHD MODELS

REMOVAL

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

1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the negative battery cable.
3. Remove the bolt that secures the liquid line fitting to the condenser outlet port (upper fitting).
4. Disconnect the liquid line fitting from the condenser outlet port.
5. Remove the O-ring seal from the liquid line fitting and discard.
6. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port.
7. If equipped, relocate the vehicle speed control servo as necessary to access the receiver/drier.

Liquid Line - 2.0L LHD Shown, RHD Typical:

8. Remove the two bolts that secure the liquid lines to the receiver/drier.
9. Remove the O-ring seals from the opened liquid line fittings and discard.
10. Install plugs in, or tape over the opened liquid line fittings and receiver/drier ports.
11. Remove the front section of the liquid line from the engine compartment.
12. Disconnect the front suction line fitting from the mid-line connector block of the rear suction and liquid line assembly.
13. Remove the O-ring seal from the front suction line fitting and discard.
14. Install plugs in, or tape over the opened front suction line fitting and the mid-line connector block of the suction and liquid line assembly.
15. Remove the bolt that secures the rear suction and liquid line assembly to the A/C expansion valve.
16. Disconnect the rear suction and liquid line assembly from the A/C expansion valve
17. Remove the gasket from the A/C expansion valve and discard.
18. Install plugs in, or tape over the opened rear suction and liquid line fittings and both expansion valve ports.
19. 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. Remove the tape or plugs from the front suction line fitting and the mid-line connector block of the suction and liquid line assembly.
8. 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.
9. Connect the front suction line fitting to the mid-line connector block.
10. 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.).
11. Position the front section of the liquid line into the engine compartment.
12. Remove the tape or plugs from the opened liquid line fittings and receiver/drier ports.
13. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the liquid line fittings. 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 fittings to the receiver/drier.
15. Install the bolts that secure the liquid line fittings to the receiver/drier. Tighten the bolts to 2.3 Nm (20 in. lbs.).
16. If equipped, reinstall the vehicle speed control servo.
17. Remove the tape or plug from the condenser outlet port and the liquid line fitting.