Refrigerant Lines

Suction Lines

Removal

1. NOTE: Plug or cap all open refrigerant lines and components to prevent entry of dirt and moisture into the A/C system. Pay particular attention to line routings to aid in installation.

   Disconnect battery ground cable.

2. Discharge A/C system. Refer to Section 12-00. Observe all safety precautions.

3. Disconnect electrical connector from A/C pressure cut-off switch (19D594).

4. Disconnect A/C manifold and tube (19D734) at suction accumulator/drier (19C836).

5. Disconnect A/C manifold and tube discharge line at A/C condenser core (19712).

6. Remove bolt retaining A/C manifold and tube to A/C compressor (19703).

7. Remove entire refrigerant line assembly from vehicle.

Installation

1. Route replacement refrigerant lines in same manner as those removed.

2. Remove any caps or plugs from connections to suction accumulator/drier and A/C manifold and tube suction line at suction accumulator/drier.

3. Lubricate both ends of refrigerant line connection using clean refrigerant oil.

4. Lubricate and install new green O-rings using clean refrigerant oil.

5. Connect A/C manifold and tube suction line to suction accumulator/drier. Finger-tighten only.

6. Remove any caps or plugs at connection to A/C manifold and tube suction line and A/C condenser core.

7. Lubricate A/C line connections at A/C condenser core and A/C manifold and tube discharge line.

8. Lubricate and install new green O-rings using clean refrigerant oil.

9. Connect A/C manifold and tube discharge line to A/C condenser core. Finger-tighten only.

10. Remove any caps or plugs from A/C manifold and tube at A/C compressor connection.

11. Lubricate and install new green O-rings in A/C manifold and tube using clean refrigerant oil.

12. Install A/C manifold and tube to A/C compressor using bolt from removal procedure. Tighten to 18 Nm (13 lb-ft).

13. Remove A/C pressure cut-off switch from old A/C manifold and tube.

14. Clean threaded portion of A/C pressure cut-off switch, wrap threads with teflon thread wrap tape and install in new A/C manifold and tube. Tighten to 7-13 Nm (62-115 lb-in).

15. Remove A/C compressor pressure relief valve (19D644) from old A/C manifold and tube and install in new A/C manifold and tube. Refer to A/C Compressor Relief Valve in the Removal and Installation portion of this section.

16. Connect electrical connector to A/C pressure cut-off switch.

17. Tighten connection at suction accumulator/drier to A/C manifold and tube suction line to 41-47 Nm (30-35 lb-ft). Use a wrench on each side of connection.

18. Tighten connection at A/C manifold and tube discharge line to A/C condenser core to 21-27 Nm (15-20 lb-ft). Use a wrench on each side of connection.

19. NOTE: When the battery (10655) has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy.

    Connect the battery ground cable.

20. Evacuate, leak test and charge the A/C system. Refer to Section 12-00. Observe all safety precautions.

21. The addition of refrigerant oil is not necessary when installing a new refrigerant line unless the line has been replaced due to bursting while containing a refrigerant charge.

Liquid Lines

Removal

1. NOTE: Cap all open refrigerant lines and components to prevent entry of dirt and moisture.

   Disconnect battery ground cable.

2. Discharge A/C system. Refer to Section 12-00. Observe all safety precautions.

3. Disconnect condenser to evaporator tube (19835) at A/C condenser core. Use a wrench on each side of the connection.

4. Disconnect condenser to evaporator tube at A/C evaporator core (19860) using Spring Lock Coupling Disconnect Tool Set T84L-19623-B. Refer to Spring Lock Coupling in the Removal and Installation portion of this section.

5. Remove condenser to evaporator tube from vehicle. Pay particular attention to line routing to aid in installation.

6. Cap or plug A/C condenser core open fitting to prevent entry of dirt or moisture.

7. Cap or plug opening to A/C evaporator core.

Installation

1. Remove shipping cap from condenser end of condenser to evaporator tube and plug or cap from A/C condenser core fitting.

2. Lubricate each end of connection using clean refrigerant oil.

3. Lubricate and install new green O-rings at line to condenser fitting.

4. Connect condenser to evaporator tube to A/C condenser core. Finger-tighten only.

5. Remove shipping cap from condenser to evaporator tube at A/C evaporator core end.

6. Remove cap or plug from A/C evaporator core.

7. Lubricate both ends of refrigerant line connection using clean refrigerant oil.

8. Lubricate and install new green O-rings on refrigerant line connection.

9. Connect condenser to evaporator tube to A/C evaporator core. Refer to Spring Lock Coupling in the Removal and Installation portion of this section.

10. Tighten condenser to evaporator tube connection at A/C condenser core to 21-27 Nm (15-20 lb-ft). Use a wrench on each side of fitting.

11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to learn the strategy.

    Connect battery ground cable.

12. Evacuate, leak test and recharge A/C system.

13. Test system for proper operation.

Discharge Lines

For more information on the removal and installation of the A/C compressor to condenser discharge line (19972), refer to Suction Lines in the Removal and Installation portion of this section.

The following illustration is a diagram of a typical refrigerant line installation.

Air Conditioning System

Item	Part Number	Description
1	18527	Blower Motor
2	—	Suction Line (Part of 19D734)
3	—	Discharge Line (Part of 19D734)
4	19D734	A/C Manifold and Tube
5	19703	A/C Compressor
6	19E762	High-Pressure Service Valve
7	19712	A/C Condenser Core
8	19835	Condenser to Evaporator Tube
9	19C836	Suction Accumulator/Drier
10	19897	A/C Evaporator Case