Liquid line

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free.

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION SECTION NEAR THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION.

FRONT

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Recover the refrigerant from the refrigerant system. See Refrigerant Recovery in the Service Procedures section of this group.

(3) Remove the screw that secures the front liquid line block fitting to the inlet of the filter-drier, and disengage the fitting from the filter-drier (Fig. 74). Install plugs in, or tape over all of the opened refrigerant line fittings.

(4) Disconnect the front liquid line refrigerant line coupler at the condenser outlet. See Refrigerant Line Coupler in the Removal and Installation section of this group for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings.

(5) Remove the front liquid line from the engine compartment.

INSTALLATION

(1) Remove the tape or plugs from the refrigerant line fittings on the front liquid line and the condenser outlet. Connect the front liquid line to the condenser outlet. See Refrigerant Line Coupler in the Removal and Installation section of this group for the procedures.

(2) Remove the tape or plugs from the front liquid line block fitting and the filter-drier inlet. Install the front liquid line block fitting to the filter-drier inlet and secure the connection with a screw. Tighten the mounting screw to 13.5 N*m (120 in. lbs.).

(3) Connect the battery negative cable.

(4) Evacuate the refrigerant system. See Refrigerant System Evacuate in the Service Procedures section of this group.

(5) Charge the refrigerant system. See Refrigerant System Charge in the Service Procedures section of this group.

REAR

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Recover the refrigerant from the refrigerant system. See Refrigerant Recovery in the Service Procedures section of this group.

(3) Remove the engine air filter housing. Refer to Group 14 - Fuel System for the procedures.

(4) Remove the nut that secures the ground strap to the inboard side of the rear liquid line block fitting.

(5) Remove the screw that secures the rear liquid line block fitting to the outlet of the filter-drier, and disengage the fitting from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings.

(6) Disconnect the suction line from the suction jumper. See refrigerant line coupler in the removal and installation section.

(7) If the vehicle is equipped with the optional rear overhead A/C unit, disconnect the refrigerant line couplers near the dash panel between the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. See Refriger- ant Line Coupler in the Removal and Installation section of this group for the procedures. Install plugs in, or tape over all of the opened refrigerant line fittings.

(8) Disengage the clip that secures the rear liquid line to the inner fender shield.

(9) Remove the nut that secures the rear liquid line block fitting to the stud on the expansion valve, and disengage the fitting from the expansion valve.

Install plugs in, or tape over all of the opened refrigerant line fittings.

(10) Remove the rear liquid line from the engine compartment.

(11) Remove the suction line jumper from the rear liquid line block fitting. See Suction Line Jumper in the Removal and Installation section of this group for the procedures.

Fig. 74 Liquid Line Remove/Install Fig. 74 Liquid Line Remove/Install

1 - FRONT LIQUID LINE

2 - SCREW

3 - HIGH PRESSURE SERVICE PORT

4 - NUT

5 - SUCTION LINE JUMPER

6 - PLASTIC RETAINER

7 - REAR LIQUID LINE

8 - GROUND STRAP

9 - LIQUID LINE EXTENSION

10 - NUT

11 - EXPANSION VALVE

12 - CLIP

13 - CONDENSER OUTLET

14 - FILTER-DRIER

15 - CLIP

INSTALLATION

(1) Install the suction line jumper into the rear liquid line block fitting. See Suction Line Jumper in the Removal and Installation section of this group for the procedures.

(2) Remove the tape or plugs from the rear liquid line block fitting and the expansion valve. Install the rear liquid line block fitting over the expansion valve stud and secure the connection with a nut. Tighten the mounting nut to 22.5 N*m (200 in. lbs.).

(3) Install the rear liquid line in the clip on the inner fender shield.

(4) If the vehicle is equipped with the optional rear overhead A/C unit, remove the tape or plugs from the refrigerant line fittings on the suction line jumper and the rear liquid line extension and both of the underbody refrigerant lines. Connect the underbody refrigerant lines to the suction line jumper and the rear liquid line extension. See Refrigerant Line Coupler in the Removal and Installation section of this group for the procedures.

(5) Remove the tape or plugs from the rear liquid line block fitting and the filter-drier outlet. Install the rear liquid line block fitting to the filter-drier outlet and secure the connection with a screw.

Tighten the mounting screw to 13.5 N*m (120 in.

lbs.). Connect the suction line from the suction discharge assembly to the suction jumper tube.

(6) Reinstall the nut that secures the ground strap to the inboard side of the rear liquid line block fitting.

Tighten the mounting screw to 6.8 N*m (60 in.

lbs.).

(7) Reinstall the engine air filter housing. Refer to Group 14 - Fuel System for the procedures.

(8) Connect the battery negative cable.

(9) Evacuate the refrigerant system. See Refrigerant System Evacuate in the Service Procedures section of this group.

(10) Charge the refrigerant system. See Refrigerant System Charge in the Service Procedures section of this group.

    Dodge Durango (DN) 1998-2003 Service Manual

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