For 1990-2009 cars

## Air Conditioning Compressor Hose Replacement Suction

### Removal Procedure

1. Recover the refrigerant using an approved refrigerant recovery system.
2. Remove the air cleaner cover and the air induction hose at the intake manifold.
3. Remove the suction hose from the thermal expansion valve (TXV).
4. Remove the suction hose from the compressor inlet.
5. Remove the suction hose from the vehicle.

### Installation Procedure

1. Remove the protective cover from the suction hose.

Important: Do not lubricate the new slim line seal washer on the compressor side of the suction hose. The slim line seal washer cannot be interchanged with a typical O-ring in the A/C system. Use only suction line slim line seal washers as a replacement.

2. Install the suction hose to the compressor inlet.

Notice: Refer to Fastener Notice in the Preface section.

3. Install and tighten the bolt.

Tighten
Tighten the suction hose-to-compressor to 25 N·m (19 lb ft).

4. Install suction line in vehicle. Route the hose around the outside of the transaxle dip stick tube, under the edge of the battery tray, and under the negative battery cable.
5. Remove the protective cover.

Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

6. Lubricate the O-ring with R-12 Refrigerant mineral oil.
7. Install the suction hose to the TXV.
8. Install and tighten the bolt.

Tighten
Tighten the suction hose-to-thermal expansion valve to 25 N·m (19 lb ft).

9. Install the air cleaner components.

## Air Conditioning Compressor Hose Replacement Discharge

### Removal Procedure

1. Recover the refrigerant using an approved refrigerant recovery system.

Important: Remove left front headlamp assembly to gain access to fitting.

2. Remove the discharge hose from compressor outlet
3. Remove the suction hose from the compressor inlet.
4. Remove the suction hose from the vehicle.

### Installation Procedure

Notice: Use only R-12 refrigerant oil to lubricate the O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints. Do not lubricate seal washers.

1. Remove the protective cover from the discharge hose.

• | Lubricate O-ring with R-12 refrigerant oil (mineral)

• | Install discharge hose to condensor inlet.

| Important: Make sure discharge hose pipe is parallel to line on radiator end tank. This will prevent the discharge hose from contacting the suction hose and transaxle oil cooler lines, preventing potential damabe to the hoses.

• | Tighten fitting.

Tighten
Tighten the discharge hose-to-condensor to 23.50 N·m (17 lb ft).

Notice: Use only R-12 refrigerant oil to lubricate the O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints. Do not lubricate seal washers.

2. Remove the protective cover from the discharge hose.

• | Lubricate O-ring with R-12 refrigerant oil (mineral)

• | Install discharge hose to compressor.

• | Tighten fitting.

Tighten
Tighten the discharge hose-to-condensor to 25 N·m (19 lb ft).

3. Evacuate, charge, and leak test the A/C system.

## Air Conditioning Compressor Hose Replacement Liquid Line

### Removal Procedure

1. Recover the refrigerant using an approved refrigerant recovery system.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Remove the hold-down retaining nut and screws and lift off the battery hold-down retainer.
5. Remove the air cleaner housing cover and the air induction hose at the intake manifold.
6. Remove the underhood fuse block cover.
7. Disconnect the electrical harness from the pressure sensor.
8. Remove the bolt holding the liquid line to the thermal expansion valve (TXV).

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

9. Raise the vehicle.
10. Remove the push nut and pull back the receiver-dehydrator splash shield.
11. Disconnect the liquid line from the receiver-dehydrator.
12. Lower the vehicle.
13. Remove the liquid line from the hold down clamps, lift the receiver-dehydrator end of the liquid line clear of the underhood fuse block.
14. Lift and rotate the TXV end of the liquid line counterclockwise to remove from the vehicle.
15. Remove the pressure sensor from the liquid line.

### Installation Procedure

Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

1. Remove the protective cover from the liquid line switch port and lubricate the O-ring.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the pressure switch to the liquid line and tighten to specifications.

Tighten
Tighten the A/C hi/lo pressure switch to 5.5 N·m (49 lb in).

3. Place tape around the protective cover on the TXV end of the liquid line to keep the cover from falling off during installation.
4. Hold the liquid line as shown. Use the pressure switch as a frame of reference.

Important: Make sure the line is behind the clutch slave cylinder hose if equipped with a manual transaxle.

5. Lower the TXV end of the line down behind the left strut tower against the cowl.
6. Rotate the line clockwise while feeding the line under and behind the brake booster.
7. Continue feeding the line along the cowl towards the TXV while lowering the receiver drier end down to the radiator support.
8. Lower the liquid line past the wiring harness and the hood release cable.
9. Lower the hood support rod.

Important: Do not bend the line around the hood support rod. After lowering the rod, gently flex the line around the radiator core support.

10. Move the receiver drier end of the line around the hood support rod and the fuse box.

Important: Install the liquid line in the front clamp located just behind the pressure switch.

11. Insert the driver end of the line through the body cut out.
12. Remove the tape and protective cover from the TXV end of the liquid line.

Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

13. Lubricate the O-ring with R-12 Refrigerant mineral oil.
14. Install the line and bolt to the TXV. Tighten the bolt.

Tighten
Tighten the liquid line-to-thermal expansion valve to 25 N·m (10 lb in).

Caution: Refer to Vehicle Lifting Caution in the Preface section.

15. Raise the vehicle.

Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

16. Remove the protective cover and lubricate the O-rings with R-12 Refrigerant mineral oil.
17. Connect the liquid line to the receiver-dehydrator. Tighten the fitting.

Tighten
Tighten the liquid line-to-receiver dehydrator to 14 N·m (10 lb ft).

18. Rotate the receiver-dehydrator splash shield into place and install the push nut.
19. Lower the vehicle.
20. Connect the electrical harness to the pressure sensor.
21. Install the underhood fuse block cover and hand tighten the screw.
22. Install the battery hold-down retainer, locking the battery into the tray.
23. Install the battery hold-down retainer nut and screws.

Tighten
Tighten the battery hold down nut to 9 N·m (80 lb in).

24. Install the air cleaner housing cover and the air induction hose.
25. Connect the positive battery cable first.

Tighten
Tighten the positive battery cable to 17 N·m (13 lb ft).

26. Connect the negative battery cable last.

Tighten
Tighten the positive battery cable to 17 N·m (13 lb ft).

27. Evacuate, charge and leak test the A/C system.
28. Set the clock to the proper time, if equipped.