Hose/Line HVAC: Service and Repair

AUXILIARY EVAPORATOR OUTLET AND INLET LINE

REMOVAL

NOTE:
- The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one piece assemblies. The replacement parts are supplied as separate kits containing multiple piece lines for ease of installation.
- The following procedure can be used to remove and install one of, or both the auxiliary evaporator inlet line and auxiliary evaporator outlet line. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.
- Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

1. Recover the refrigerant. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, Refrigerant Discharging and Recovery procedure







2. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line.

Remove the nut(s) and disconnect the A/C fitting(s).

3. Remove the RH quarter trim panel.
4. Remove the spare tire.







5. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed.

Disconnect the A/C fittings.
- Install new O-rings lubricated in clean PAG oil.







6. Remove the bolts and the line bracket.
7. Raise the vehicle.
8. Remove the spare tire carrier splash shield.
9. Remove the RH front wheel.
10. Remove the RH fender splash shield.
11. Remove the muffler.
12. Remove the RH catalytic converter.







13. Remove the three bolts and the heat shield.







14. Remove the bolts.







15. Remove the nut and the line bracket.







16. Remove the bolt and the heat shield.







17. Remove the nuts and the remaining line brackets.

18. NOTE: If installing only one auxiliary evaporator line, cut only the desired line.

Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s).

19. Remove the auxiliary evaporator line(s) in three separate pieces.

INSTALLATION
1. Partially lower the vehicle to allow access to both the rear auxiliary line fittings and the underside of the vehicle.







2. Position the rear portion of the auxiliary evaporator line(s) and install the line bracket and bolts.







3. Connect the A/C fittings.







4. Install the front auxiliary evaporator line(s) and connect the A/C fittings.
- Install new O-ring seals lubricated in clean PAG oil.

5. Raise the vehicle.







6. NOTE: Loosely connect, but do not tighten, the fittings.

Install the middle auxiliary evaporator line(s).







7. Starting from the rear of the vehicle, install the first three line brackets.







8. Tighten the middle auxiliary evaporator line fittings.
9. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed.







10. Install the heat shield and the bolts.







11. Install the heat shield and the bolts.
12. Install the RH catalytic converter.
13. Install the muffler.
14. Partially lower the vehicle.







15. Install the heat shield bolt.







16. Install the line bracket.
17. Install the spare tire carrier splash shield.
18. Install the RH front fender splash shield.
19. Install the RH front wheel.
20. Lower the vehicle.
21. Install the RH quarter trim panel.
22. Install the spare tire.
23. Lubricate the refrigerant system with the correct amount of clean PAG oil.
24. Evacuate, leak test and charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging, Evacuation and Charging