7. Remove the secondary retaining clip (7) from the
spring-lock coupler (1) that secures the A/C suction
line (6) to the accumulator (5).
8. Using the proper A/C line disconnect tool, discon-
nect the A/C suction line from the A/C accumulator
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/COUPLER-REFRIGERANT LINE -
REMOVAL).
9. Remove the O-ring seals from the accumulator
tube fitting and discard the seals.
10. Install plugs in, or tape over the opened suction
line fitting and the accumulator outlet tube.
11. Remove the A/C suction line from the engine
compartment.
5.7L ENGINE
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Disconnect and isolate the negative battery cable.
3.Removetheairfilterhousing(Referto9-
ENGINE/AIR INTAKE SYSTEM/AIR FILTER
HOUSING - REMOVAL).
4. Remove the nut (4) that secures the A/C suction
line (5) to the A/C compressor (6).
5. Disconnect the A/C suction line from the A/C com-
pressor and remove and discard the O-ring and
dual plane seal.
6. Install plugs in, or tape over the opened refrigerant
line fitting and the compressor port.
7. Remove the secondary retaining clip (7) from the
spring-lock coupler (1) that secures the A/C suction
line (6) to the A/C accumulator (5).
8. Using the proper A/C line disconnect tool, discon-
nect the A/C suction line from the A/C accumulator
and remove and discard the O-ring seals (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
COUPLER-REFRIGERANT LINE - REMOVAL).
9. Install plugs in, or tape over the opened suction
line fitting and the accumulator outlet tube.
10. Remove the A/C suction line from the engine
compartment.
5.9L DIESEL ENGINE
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
NOTE: The A/C suction line for the 5.9L Diesel engine is serviced as an assembly with the discharge line.
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Disconnect and isolate the negative battery cable.
3. Remove the air filter housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM).
4. Remove the secondary retaining clip (7) from the
spring-lock coupler (1) thatsecures the suction line
(6) to the A/C accumulator (5).
5. Using the proper A/C line disconnect tool, discon-
nect the suction line from the A/C accumulator and
remove and discard the seals (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/COU-
PLER-REFRIGERANT LINE - REMOVAL).
6. Install plugs in, or tape over the opened accumula-
tor tube fitting.
7. Disconnect the wire harness connector (5) from the
A/C pressure transducer (4).
8. Remove the nut (2) that secures the A/C suction
and discharge line assembly (3) to the A/C con-
denser (1).
9. Disconnect the discharge line from the A/C con-
denser and remove and discard the seal.
10. Remove the bolt (7) that secures the A/C suction
and discharge line assembly to the A/C compres-
sor (6).
11. Disconnect the A/C suction and discharge line
assembly from the A/C compressor and remove
and discard the seals.
12. Remove the A/C suction and discharge line
assembly from the engine compartment.
13. Install plugs in, or tape over the opened refriger-
ant line fittings and condenser and compressor
ports.
14. If necessary, remove the A/C pressure transducer from the A/C dischargeline(Referto24-HEATING&AIR
CONDITIONING/CONTROLS/TRANSDUCER-A/C PRESSURE - REMOVAL).
8.3L ENGINE
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Disconnect and isolate the negative battery cable.
3. Remove the bolt (5) that secures the A/C suction
line (1) to the A/C compressor (2).
4. Disconnect the A/C suction line from the A/C com-
pressor.
5. Remove the seal and gasket from the suction line
fitting and discard.
6. Install plugs in, or tape over the opened suction
line fitting and the compressor inlet port.
7. Remove the A/C suction line (5) from the refriger-
ant line retainer clips (2) located at the top of the
fanshroud(1).
8. Remove the air filter housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR FILTER
HOUSING - REMOVAL).
9. Remove the secondary retaining clip (7) from the
spring-lock coupler (1) that secures the A/C suction
line (6) to the accumulator (5).
10. Using the proper A/C line disconnect tool, discon-
nect the A/C suction line from the A/C accumula-
tor(Referto24-HEATING&AIR
CONDITIONING/PLUMBING/COUPLER-REFRIG-
ERANT LINE - REMOVAL).
11. Remove the O-ring seals from the accumulator
tube fitting and discard the seals.
12. Install plugs in, or tape over the opened suction
line fitting and the accumulator outlet tube.
13. Remove the A/C suction line from the engine
compartment.
INSTALLATION
3.7L/4.7L ENGINES
1. Position the A/C suction line (5) into the engine
compartment.
2. Remove the tape or plugs from the opened fitting
on the A/C suction line and the inlet port on the
A/C compressor (6).
3. Lubricate a new seal with clean refrigerant oil and
install it onto the suction line fitting. Use only the
specified seal as it is made of a special material for
the R-134a system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
4. Install the A/C suction line onto the A/C compres-
sor.
5. Install the nut (4) that secures the A/C discharge
line to the A/C compressor. Tighten the nut to 20
Nꞏm (15 ft. lbs.).
6. Remove the tape or plugs from the opened suction
line fitting and the accumulator outlet tube.
7. Lubricate new rubber O-ring seals with clean refrig-
erant oil and install them onto the accumulator tube
fitting. Use only the specified O-rings as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended
for the A/C compressor in the vehicle.
8. Connect the A/C suctionline (6) to the spring-lock
coupler (1) on the accumulator (5) and install the
secondary retaining clip (7) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/COU-
PLER-REFRIGERANT LINE - INSTALLATION).
9. Install the air filter housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR FILTER
HOUSING - INSTALLATION).
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
12. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
5.7L ENGINE
1. Position the A/C suction line (5) into the engine
compartment.
2. Remove the tape or plugs from the opened fitting
on the A/C suction line and the inlet port on the
A/C compressor (6).
3. Lubricate a new O-ring and dual plan seal with
clean refrigerant oil and install them onto the suc-
tion line fitting. Use only the specified seals as they
are made of a special material for the R-134a sys-
tem. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
4. Install the A/C suction line onto the A/C compres-
sor.
5. Install the nut (4) that secures the A/C discharge
line to the A/C compressor. Tighten the nut to 20
Nꞏm (15 ft. lbs.).
6. Remove the tape or plugs from the opened suction
line fitting and the accumulator outlet tube.
7. Lubricate new rubber O-ring seals with clean refrig-
erant oil and install them onto the accumulator tube
fitting. Use only the specified seals as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended
for the A/C compressor in the vehicle.
8. Connect the A/C suctionline (6) to the spring-lock
coupler (1) on the accumulator (5) and install the
secondary retaining clip (7) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/COU-
PLER-REFRIGERANT LINE - INSTALLATION).
9. Install the air filter housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR FILTER
HOUSING - INSTALLATION).
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
12. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
5.9L DIESEL ENGINE
NOTE: The A/C suction line for the 5.9L Diesel engine is serviced as an assembly with the discharge line.
1. If removed, install the A/C pressure transducer (4)
onto the A/C suction and discharge line assembly
(3)(Referto24-HEATING&AIRCONDITION-
ING/CONTROLS/TRANSDUCER-A/C PRESSURE
- INSTALLATION).
2. Remove the tape or plugs from the opened refrig-
erant line fittings and the condenser and compres-
sor ports.
3. Position the A/C suction and discharge line assem-
bly into the engine compartment.
4. Lubricate new seals with clean refrigerant oil and
install them onto the refrigerant line fittings. Use
only the specified seals as they are made of a spe-
cial material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
5. Connect the A/C suction and discharge line assem-
bly to the A/C condenser (1).
6. Install the nut (2) that secures the discharge line to the A/C condenser.Tighten the nut to 20 Nꞏm (15 ft. lbs.).
7. Connect the A/C suction and discharge line assembly to the A/C compressor(6).
8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the
boltto23Nꞏm(17ft.lbs.).
9. Connect the wire harness connector (5) to the A/C pressure transducer.
10. Remove the tape or plugs from the opened accu-
mulator tube fitting.
11. Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the accumula-
tor tube fitting. Use only the specified O-rings as
they are made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
12. Connect the suction line (6) to the spring-lock
coupler (1) on the accumulator (5) and install the
secondary retaining clip (7) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/COU-
PLER-REFRIGERANT LINE - INSTALLATION).
13. Install the air filter housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM).
14. Reconnect the negative battery cable.
15. Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE).
16. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
8.3L ENGINE
1. Remove the tape or plugs from the opened suction
line fitting and the accumulator outlet tube.
2. Lubricate new rubber O-ring seals with clean refrig-
erant oil and install them onto the accumulator tube
fitting. Use only the specified O-rings as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended
for the A/C compressor in the vehicle.
3. Connect the A/C suctionline (6) to the spring-lock
coupler (1) on the accumulator (5) and install the
secondary retaining clip (7) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/COU-
PLER-REFRIGERANT LINE - INSTALLATION).
4. Install the A/C suction line (5) into the two refriger-
ant line retainer clips (2) located at the top of the
fanshroud(1).
5. Install the air filter housing cover (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR FILTER
HOUSING - INSTALLATION).