Page 5177 of 5267

REAR SECTION
1. Position the rear section of the A/C liquid line (3)
into the engine compartment.
2. Remove the tape or plugs from the opened ends of
the A/C liquid lines and the evaporator inlet tube
(7).
3. Lubricate a new seal with clean refrigerant oil and
install it on the rear liquid line spring-lock coupler
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. Connect the rear section of the A/C liquid to the
evaporator inlet tube (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/COUPLER-RE-
FRIGERANT LINE - INSTALLATION).
5. Install the secondary retaining clip (6) onto the
spring-lock coupler that secures the rear section of
the A/C liquid to the evaporator inlet tube.
6. Engage the A/C liquid line into the body retaining clips.
7. Lubricate a new seal with clean refrigerant oil and install it on the front liquid line spring-lock coupler 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.
8. Connect the rear section of the A/C liquid to the front section of the liquid line (1) (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/COUPLER-REFRIGERANT LINE - INSTALLATION).
9. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid
to the rear section of the liquid line.
10. Install the air filter housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR FILTER HOUSING - INSTALLA-
TION).
11. Reconnect the negative battery cable.
12. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
13. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
Page 5178 of 5267

LINE-A/C SUCTION
DESCRIPTION
The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor.
TheA/Csuctionlineforthe5.9LDieselengineisservicedasanassemblywith the discharge line.
The A/C discharge line for the 8.3L engine is secured to the top of fan shroudby two retainers.
CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause
the refrigerant system connections to leak.
The A/C suction line has no serviceable parts except for the rubber O-ring seals and the secondary retaining clip.
The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refriger-
ant. The O-ring seals must be replaced whenever the A/C suction line is removed and installed.
If the A/C suction line is found to be leaking or is damaged, it must be replaced.
REMOVAL
3.7L/4.7L ENGINES
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 air filter housing cover (Refer to 9 -
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 seal.
6. Install plugs in, or tape over the opened refrigerant
line fitting and the compressor port.
Page 5179 of 5267

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.
Page 5180 of 5267

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.
Page 5181 of 5267

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.
Page 5182 of 5267
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.
Page 5183 of 5267

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).
Page 5184 of 5267

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.