Suction and discharge 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. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose.

In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

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. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

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

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) Unplug the wire harness connector from the high pressure cut-off switch.

(4) Disconnect the refrigerant line couplers at the condenser and the suction line jumper. 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 nut that secures the refrigerant line support bracket near the compressor.

(6) Remove the screw that secures the refrigerant line manifold to the compressor (Fig. 84). Install plugs in, or tape over all of the opened refrigerant line fittings.

(7) Remove the suction and discharge line assembly from the vehicle.

INSTALLATION

(1) Remove the tape or plugs from all of the refrigerant line fittings. Install the refrigerant line couplers to the condenser and the suction line jumper.

See Refrigerant Line Coupler in the Removal and Installation section of this group for the procedures.

(2) Install the refrigerant line manifold to the compressor.

Tighten the mounting screw to 22 N*m (200 in. lbs.).

(3) Install the nut that secures the refrigerant line support bracket near the compressor.

(4) Plug in the wire harness connector to the high pressure cut-off switch.

(5) Connect the battery negative cable.

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

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

Fig. 84 Suction and Discharge Line Remove/Install

1 - SUCTION AND DISCHARGE LINE ASSEMBLY

2 - EXPANSION VALVE

3 - LINE CLIP

4 - LOW PRESSURE SERVICE PORT

5 - HIGH PRESSURE CUT-OFF SWITCH

6 - CONDENSER